TPM method helps businesses improve productivity, product quality and labor safety

TPM is a management approach towards innovation in maintenance activities with the participation of all employees in the enterprise. TPM ensures equipment efficiency, improves productivity, product quality and a safe working environment. In Vietnam, for many years, in the process of implementing the National Program on “Improving productivity, product and goods quality of Vietnamese enterprises up to 2020”, many businesses have bravely applied Use the TPM method and achieve many positive results.

Benefit from overall device performance maintenance method

According to the Vietnam Productivity Institute, the Total Productive Maintenance (TPM) method is a management method first applied in Japan, then popularized and widely applied in manufacturing industries worldwide.

According to this method, the operators must take care of the daily maintenance work while the specialized maintenance department will manage and undertake important maintenance tasks periodically. The concept and method of TPM was first introduced by the Japan Institute of Plant Maintenance (JIPM) in 1971. Starting in the 1980s, TPM began to be popularized outside Japan thanks to the book “About Introduction to TPM and the TPM Development Program ”by Seiichi Nakajima – an expert from JIPM.

Understandably, TPM is effective maintenance with everyone involved – a combination of effective maintenance (PM) and a comprehensive Quality Management (TQM). Many organizations misunderstand about TPM when they think that only factory workers need to participate. In fact, to be effective, TPM needs to be implemented effectively on an organizational basis. The TPM implementation is aimed at maximizing equipment efficiency, improving productivity with a maintenance system that is implemented throughout the device’s life cycle, while raising awareness and job satisfaction. labor. With TPM, people join forces and interact with each other to improve the performance of the device in the most efficient way.

TPM focuses heavily on the hardware of the production system in an organization, so the most appropriate objects are organizations and businesses with production activities, in which the machinery and equipment involved contributes greatly to the create a product and play an important role in creating that product quality.

It can be said that TPM is a management approach towards innovation in maintenance activities with the participation of everyone in the business. TPM ensures equipment efficiency, improves productivity, product quality and a safe working environment. TPM is a program, operating with a long-term and persistent strategic vision, requiring several years of corporate efforts to successfully implement and sustain.

According to experts on quality productivity, it is easy to see a range of benefits for businesses when applying the TPM method such as: Increasing productivity and overall equipment performance index (OEE); Minimize production costs due to broken or stopped machines; Improve the ability to meet the schedule in production; Do not let the accident occur; Encourage workers’ innovation initiatives; Sharing experiences; Improve the working environment, etc.

Positive effects and prospects apply in Vietnam

In Vietnam, for many years, in the course of implementing the National Program on “Improving productivity, product and goods quality of Vietnamese enterprises up to 2020” of the Government, many enterprises have boldly applied the TPM method and achieved many positive results.

In 2018-2019, the Ministry of Industry and Trade supported 24 typical enterprises to apply TPM tools. The main activities have been implemented in 24 typical enterprises, including guidance activities on pillars AM, PM, FI, HSE, E&T, etc; build and maintain processes for managing and maintaining equipment; Internal training towards the goal of zero defects, no downtime, no loss and no accidents. In the period of 2019-2020, the Ministry of Industry and Trade has organized a program of consulting support for TPM factories and manufacturing companies through the task of “Building and applying TPM tools and software for industrial production enterprises ”aims to further disseminate and expand the benefits that TPM brings to businesses. In particular, over the past time, we can mention a series of typical TPM tools such as Tri Cuong Industry Co., Ltd. Southern Engine and Agricultural Machinery Company Limited (SVEAM); Tan Huy Hoang Banking Equipment Center; Son Hai Phong Joint Stock Company (JSC); Duy Khanh Mechanical Company Limited; Cuong Vinh Company, etc.

Accordingly, after only a short time, applying TPM under the project “Improving productivity and product quality, industrial goods” of the Ministry of Industry and Trade, Tri Cuong Industrial Co., Ltd. (TCI) has initially started. effective. Accordingly, in order to improve productivity and productivity in production, TCI has responded to the program of applying TPM to the Ministry of Industry and Trade’s production from August 2019 and started to deploy from October to December 2019. . In just a short time, TCI quickly established the foundation for 3 pillars of deployment with the scope of application at CNC milling machine 1-2, CNC lathe 2 in production room No. 1. In addition, the Company has gained benefits in visual management, staff discipline, production management and equipment efficiency.

Specifically, TPM’s behavior, routines, and results are updated weekly to the working group on Zalo social network. The operator has been clearly assigned the duties and scope of the operation, so efforts have been made to take care of equipment maintenance (AM Pillars) and maintain daily equipment inspection frequency. During the implementation of TPM project, the company has started an improvement project with the participation of the production manager 1, the manager of the production equipment maintenance department 1, the production leader, the CNC team leader and maintenance personnel. Regarding production management, TCI has trained and instructed the inspection and operation of equipment for equipment operators (2 people in charge of 2 pilot machines) under the AM pillar, so the machines have been taken care of. and better maintenance, more clean. Long-term solutions have been applied in place of previous temporary solutions such as using ropes to temporarily bundle pipes, rags to handle water and gas leaks, etc, TCI has reduced product conversion time through improvements (reducing clearance time from 21 minutes to 15 minutes) which helps improve overall OEE equipment performance of CNC milling machines from 38% (November) up 50% (December) and OEE CNC lathes from 73% (November) to 76% (December). In terms of safety effectiveness, the re-planning of tools as well as standardization of operations should make the ground more reasonable and wider, thereby helping workers move less, thereby increasing worker safety when participating in operations, etc.

In order to improve the productivity of product quality, Southern Engine and Agricultural Machinery Company Limited (SVEAM) – an enterprise specializing in manufacturing leading machinery and equipment in the field of agriculture and fishery in Vietnam and the region. Southeast Asia has also applied TPM in production. Accordingly, within the framework of the program: “Supporting the pilot application of TPM tools for Industry enterprises” of the Ministry of Industry and Trade for 24 enterprises in the period of 2018-2019, SVEAM’s Board of Directors has registered to participate. joined the program from September 2018 with the scope of application at the hip lid line of mechanic workshop No. 1. As a result, after the implementation and implementation of TPM, SVEAM has achieved many encouraging results such as: Better visual management; There are more improvements on tool placement at the device, etc.

In particular, in terms of productivity efficiency, the OEE overall equipment performance index in the pilot deployment area increased compared to the period of August 2018. Specifically, the value of OVE in August 2018 of SVEAM is 87.39%; and OEE in August 2019 is 94%; The months from 10/2018 to 6/2019 are 85% larger than the target value, and the highest OEE value is 94% in August 2019. In terms of training effectiveness, the M&E Department is capable of training about TPM for other workshops in the company. In particular, training has been replicated for the first Mechanical Workshop, and the No. 1 Mechanical Workshop for self-deploying TPM (self-replication). The M&E Department has assessed the capacity for 100% (7/7 of M&E staff). Regarding visual management, over the first 3 months of implementing TPM, 5S activities have been strengthened throughout the Company. In particular, regarding the manners and routines of the members of the TPM pilot area (the hip cap line) all comply with the production diary, perform cleaning every 10 minutes every morning and the M&E office have weekly check for abnormalities, etc.

Another good example is Hai Phong Son JSC. Accordingly, to help improve and standardize the skills of the operator in the care and maintenance of equipment, Son Hai Phong No. 2 JSC has decided to apply the self-service maintenance pillar with TPM card. The activities in the AM pillar applied at Son Hai Phong Joint Stock Company No. 2 include: At the beginning, the Company encouraged workers to actively participate in tagging to improve skills and awareness of abnormal detection. even the smallest errors such as dirty machine, paint peeling machine, lost screws, etc. As a result, the Company has attached and dealt with 54 red and green TPM cards; Standards of hygiene, inspection, lubrication of equipment have been developed for crushers and extruders, and have been instructed by the mechanical and electrical department chief for the workers operating at these two machines. Thereby, reducing the workload to protect maintenance staff and resources, costs of the Company, etc.

Many business leaders affirmed that, with the benefits and results gained from TPM tool, to continue sustainable development, these companies continue to maintain and make more efforts to expand TPM to bring greater efficiency in improving productivity and quality, contributing to improving production efficiency of the business.

Productivity and Quality Office