Two methods: one efficient solution
January 1st 2008

Implementation of a Total Productive Maintenance (TPM) programme within any organisation is difficult and considerably more applications have failed than have succeeded. Roy Davis of MPI outlines what he considers to be the problems and suggests an integrated solution

Among possible reasons for the failure of a TPM programme are factors such as: A 'half hearted' attempt to introduce TPM being made. This is usually as a result of a lack of understanding of the underlying principles of TPM and/or a lack of will to make it work because it has been enforced by senior management and middle managers and line managers have not 'bought in' to the concept.

The initial introduction has started off well but has gradually faded due to a lack of enthusiasm, supporting structure or practical methods of sustaining the programme in the longer term

The initial expectations for TPM were much too high and an over-ambitious programme was proposed which could not be practically achieved due to a number of reasons and in particular a lack of resources

Most companies find it almost impossible to provide the resources and on-going commitment required to achieve a full TPM programme and either dismiss it as 'too difficult' or try it and fail, probably for the reasons stated above.

TPM is very much a people orientated approach which involves production personnel as well as engineering personnel and seeks to fundamentally change the way in which the shop floor operates and puts in place continuous improvement mechanisms aimed at plant, machinery and the workplace.

Reliability Centred Maintenance (RCM) is a very different approach as it is much more engineering biased than TPM and is aimed primarily at plant and machinery assets. An RCM study will:

Identify the degree of criticality of each plant and machinery asset so that resources can be focussed on the most important assets

Examine the main components and elements within each plant and machinery asset and assess the degree of risk associated with each component

Enable a maintenance regime to be developed and implemented for each asset that is based upon its criticality to the business and the risk associated with its main components.

The author has developed a maintenance approach which combines the risk based elements of Reliability Centred Maintenance with the team working, ownership and people involvement of Total Productive Maintenance.

The approach has been applied in a number of industrial companies and has shown that benefits can be achieved by integrating the two approaches which have previously been regarded by some as being very different and sometimes even conflicting.

There has been a tendency in the past for proponents of RCM and TPM to be very dogmatic and inflexible about either approach. The author has found however, that RCM and TPM complement each other as RCM is an extremely effective method of establishing asset criticality and the most at risk components within each asset and TPM is very good at bringing production and engineering personnel together to develop cost-effective maintenance schedules based upon the RCM analysis which they have been involved in the development of, understand the reason for production based and engineering based activities and therefore will own and support the maintenance programme.

Depending upon the situation prevailing within a particular company there is usually a choice as to whether the programme commences with the introduction of some basic TPM principles and activities and then gradually builds upon this and RCM is introduced at a later stage or alternatively, the programme commences with an RCM study in order to develop cost-effective maintenance schedules which include production activities, and improvement opportunities are identified. TPM activities can then follow on naturally from the RCM study.

MPI provides a range of training and 'hands on' support services focussed on introducing and implementing the RCM/TPM approach and aimed at achieving the most cost-effective maintenance schedules for customers.