The Importance of TPM and SMED

There are two main types of manufacturing environments that I have worked in.  One is a heavy manual operation environment usually assembly lines.  The other is a heavy machining environment with painting and plating lines or injection molding machines, etc…

In a heavy machining manufacturing environment, there are two lean concepts that I believe need to be done very well to have sustained success…Total Productive Maintenance (TPM) and Quick Changeover (SMED).

Some may say continuous flow is the most important concept.  The issue is flow can not happen if the machines are down unexpectedly or if the changeovers are taking a long time.

If a machine goes down, then flow stops all together or WIP is built up between the processes so when the machine goes down unexpectedly the following process does not go down also.

The longer a changeover takes the more WIP needs to be built up in front of the next process.

In either case, this causes the flow to be interrupted. Any WIP that is introduced between the process interrupts the flow of that particular item even when things are running smoothly.  The item has to stop and wait will the items in queue in front of it go through the process first.  This can make it difficult to link processes together to create the smooth flow.

Yet, these are two tools that I rarely see as a high priority to master in a manufacturing environment.  5S seems to be the tool to try and master first and then standard work.  I do believe these are extremely valuable and necessary concepts, but if you don’t implement them trying to solve a particular business need then sustaining the gains is hard.

5S and standardized work can both be implemented through a TPM and SMED program.  5S can be used so tools are in their place and ready to go when a changeover is taking place or maintenance is being done so the machine is down for less time and production can start back up.  There should be standardized work to make sure the TPM is happening.  Checklists is a common way to have standardized work for TPM.  There should also be standardized work for changing over a machine in the quickest, safest, most efficient manner that is known.

All the concepts are important.  I see TPM and SMED as two concepts that are vehicles to other concepts introduction and success.

Are there other areas TPM and SMED are as important?  Maybe with IT systems?

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Posted on November 21, 2011, in Manufacturing, Tools, Waste and tagged , , , , , , . Bookmark the permalink. 2 Comments.

  1. Matt,

    TPM is very beneficial in automated food and beverage manufacturing plants as well. It provides the systems and structure for sustained improvements. I’m currently working with a couple food companies and 5 AM teams. All of them are seeing a 25-50% reduction of downtime with other benefits like improved quality. The best part is that the lines continue to perform at a new level.

    Best regards,
    Chris

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