TPM Reloaded. Joel Levitt

team work

      • Better relationships with maintenance

      • More challenge and more fun

      Maintenance Department

      The maintenance department can be a great asset in TPM or an anchor to old ways of working. They are now team members lending specific expertise to the TPM team. They are relieved from having to do basic (boring) maintenance and PM. They can concentrate on higher level issues. We also have to address the fears that this kind of change brings on in maintenance workers.

      The obvious linkage is between the transfer of workload and near-term layoffs of expensive maintenance workers. This is a real fear that must be addressed. If there are going to be layoffs, please hold off on your TPM adoption until the labor situation settles down. In fact, the workload might increase after TPM is even partially operational because maintenance will be working on projects geared toward improvements of various kinds.

      Benefits of TPM for Maintenance Personnel

      • Crafts people receive additional training

      • More time available for high level Preventive and Predictive Maintenance, projects, and analytics.

      • Higher level of expertise in maintenance

      • Better relationships with production people

      • Crafts people become more valuable to the company

      • More cooperative work environment from teamwork

      • More fun because of new relationships and sharing problem solving

      • Less routine work for lubrication, cleaning, adjustments, inspection, and minor repairs

      • Greater ability to troubleshoot and given time get to the root cause

      • More appreciation from production of complexity of maintenance job

      • Higher morale from improved job satisfaction and job security

The Value Calculator for TPM and Lean Manufacturing

      Exhibit 2-2 on the following page shows a sample of the form for estimating costs, benefits, and ROI. This form can be found at http://wcm.nu/economy/tpm.htm