Potential of Implementing Total Productive Maintenance (TPM) on a Small-Scale Machine Shop

Abstract

Introduction: Total Productive Maintenance (TPM), which originated in Japan's industrial sector, is a comprehensive approach aimed at optimizing production systems by actively involving all employees in the upkeep and maintenance of machinery and equipment. When TPM principles are effectively applied, they significantly reduce the risk of equipment failures and drive productivity to its maximum potential. This paper delves into the feasibility of implementing TPM in small-scale machine shops, with a specific focus on improving the quality and efficiency of wheel rim replacement processes.

Objectives: The primary objective is to assess the existing practices in a small-scale machine shop and pinpoint areas where TPM can be introduced to drive improvements. This study seeks to address key challenges, such as cutting irregularities and outdated equipment, that currently hinder productivity and quality. Through the application of root cause analysis, the paper aims to identify and implement solutions that will enhance operational efficiency and minimize waste in the wheel rim replacement process.

Methods: Implementing a Total Productive Maintenance (TPM) program fosters a shared responsibility for equipment maintenance, encouraging greater involvement from all levels of plant floor workers, which can significantly boost productivity. In a small-scale machine shop, TPM emphasizes that maintenance should be a collective effort, engaging not only the maintenance team but all employees, including top management, in the upkeep of equipment. By applying the 5S principles and Autonomous Maintenance (AM), the shop can create a more organized and efficient environment, making it easier to identify and address problems, thus restoring equipment to its optimal operating condition.

Results: The observation of a small-scale machine shop's operations revealed that neglecting the foundational 5S principles can lead to significant negative outcomes, including delays, defects, and declining employee morale. The shop's failure to consistently apply 5S practices, such as organizing tools and maintaining a clean workspace, contributed to inefficiencies and potential safety risks. Furthermore, the limited availability of functional lathe machines and inadequate maintenance practices resulted in increased downtime, affecting overall productivity and quality.

Conclusions: The implementation of TPM in a small-scale machine shop requires a proactive approach, ensuring that quality and productivity are prioritized even before the work process begins. Success hinges not only on the workers' efforts but also on the active involvement and support of management, including the acquisition of necessary facilities to enhance working conditions. Management must be prepared to address the challenges and risks associated with TPM implementation, potentially conducting a cost-benefit analysis to ensure the initiative's profitability and long-term growth.