Since the beginning of time,
humans have always felt the need for the
maintenance of their equipment, even the most rudimentary tools. Most of the
failures experienced have been a result of abuse, as it sometimes still happens. First,
they would do maintenance only when it was no longer possible to run it. That was called
“Breakdown or Reactive Maintenance”.
It was until
1950 that some groups of Japanese engineers started a new concept in maintenance that
consisted on following the manufacturers’ recommendations about the care that should
be taken in the operation and maintenance of the machines and devices. That new trend was
called “Preventive Maintenance”. As a result, plant managers were
encouraged to have their supervisors, mechanics, electricians and other specialists,
develop programs for lubricating and making key observations to prevent damages of the
equipment. Although it helped reduce down-time, it was an expensive alternative. The
reason: Many parts were replaced on a time-basis, while they could've lasted longer. Also
many unnecessary man-hours were put into it and in not few cases excess
lubrication caused more damage than good.
The times and
needs changed, in 1960 new concepts were established, “Productive Maintenance”
was the name for the new trend which determined a more professional approach. The
assignment of a higher responsibility to all the people related to maintenance consisted
of a series of considerations about the reliability and design of the equipment and the
plant itself. The change was so profound that the term “Maintenance” was changed
to “Plant Engineering” and the tasks to be performed, included a higher
understanding of the reliability of each element of the machines and installations in
general.
Just a decade
later, the globalization of the marketplace created new, stronger needs for excellence in
all activities. The World-Class standards In terms of equipment maintenance were
understood, a dynamic system was created. TPM, is a continuous improvement concept that
has proven to be effective, first in Japan and now back in America (where the concept was
first created). It is about the involvement and participation of each and everyone of the
members in the organization towards optimizing the outcome of each piece of equipment.
This is a
completely new philosophy, a different approach that will keep updated by itself. It
implies a continuous improvement in all aspects and is called TPM.
As we stated in
the Definition, TPM stands for “Total Productive Maintenance” and may also
for “Total Participation Maintenance”.
The purpose is
to transform the attitude of all the members of the industrial community, all kinds and
levels of workers, operators, supervisors, engineers, administrators are included in this
major responsibility. ”TPM implementation” is a goal that we all share. It also
generates benefits for all of us. Through this effort, we all are responsible for the
up-keeping of the equipment. It becomes more productive, safer and easier to operate and
even looks nicer. The participation of people who are not familiar with the
equipment and its operation, enriches the results because their observations are in many
cases more objective than those of the people who live with the equipment in a daily
basis.
TPM
in America
