How Do Total Productive Maintenance Consultants Assess Equipment Efficiency
TPM consultants use several methods and strategies to implement TPM. One of the major principles of TPM is to increase equipment efficiency. But in order to increase it, one must assess the equipment’s efficiency and then devise a strategy accordingly. When it is done like that, you will be able to increase overall equipment effectiveness (OEE), minimize downtime, and increase productivity. Therefore, in this article, we will deep dive into the methods and strategies TPM consultants use to evaluate and improve equipment efficiency.
How do TPM consultants Assess Equipment Efficiency?
The foundation of equipment efficiency assessment lies in understanding and calculating OEE. OEE is a comprehensive metric that considers three critical factors: availability, performance, and quality. Popular firms like the TPM consultants in Pune have excellent strategies and they usually start by gathering data on these factors to establish a baseline for equipment performance.
Availability Analysis
Availability refers to the percentage of time equipment is operational and available for production compared to the total scheduled time. TPM consultants analyze machine logs, maintenance records, and downtime reports to identify periods when equipment was not operational. They categorize downtime into planned and unplanned events, such as maintenance, setup, or unexpected breakdowns.
Performance Evaluation
Performance measures the speed at which equipment operates relative to its maximum designed speed. Consultants examine production data to determine if machines are running at optimal speeds. They identify factors that may cause reduced performance, such as operator errors, equipment wear, or suboptimal settings.
Quality Assessment
Quality evaluates the proportion of good parts produced compared to the total parts produced. Consultants scrutinize defect rates, rework instances, and scrap data to gauge the quality of output. They work with quality control teams to understand the root causes of defects and implement corrective actions.
Root Cause Analysis
Identifying the root causes of inefficiencies is a critical step in the assessment process. TPM consultants employ various root cause analysis techniques, such as:
●5 Whys: This method involves asking “why” repeatedly until the underlying cause of a problem is identified.
●Fishbone Diagrams: Also known as Ishikawa diagrams, these visual tools help map out potential causes of a problem, categorized into areas such as equipment, processes, and personnel.
●Pareto Analysis: This technique helps prioritize issues by identifying the most significant factors contributing to inefficiencies.
Implementing Corrective Actions
After identifying the root causes, TPM consultants collaborate with maintenance and production teams to develop and implement corrective actions. These actions may include:
●Preventive Maintenance Programs: Regularly scheduled maintenance tasks to prevent equipment failures and extend the lifespan of machinery.
●Standard Operating Procedures (SOPs): Clear and concise instructions for equipment operation and maintenance to reduce operator errors and improve consistency.
●Training and Development: Providing training programs for operators and maintenance staff to enhance their skills and knowledge.
Conclusion
These are the strategies implemented by TPM consultants to evaluate, assess, and implement TPM to increase the OEE. Once this is perfectly done and implemented, you can see a significant increase in productivity and efficiency.