Total Productive Maintenance 141

administration

The department within an organization that is responsible for clerical tasks. Administration duties include recording and organizing information, coordinating schedules, managing correspondence, and ensuring all necessary materials used during production are available.

audits

An examination of a company's activities or products to determine if a company is in compliance with standards. Audits must be completed both internally and externally.

autonomous maintenance

A maintenance approach in which tasks, such as lubricating or cleaning, are performed by the machine operator rather than the maintenance staff. Autonomous maintenance is one of the eight pillars of total productive maintenance.

availability

The amount of time a machine is actually ready for production, expressed as a percentage of the time that it should be available. Availability is calculated by dividing the amount of time a machine actually spends producing parts by the amount of time it is expected to produce parts.

baseline

The initial data collected while a system or component is working under its usual conditions. Baseline readings are compared to future readings in order to detect potential problems or measure improvements.

basic condition

The expected good state of repair that equipment should be in so that it can produce quality parts in a timely manner. The basic condition of machines can be maintained through regular cleaning and preventive maintenance.

breakdowns

A malfunction that prevents a component or process from operating correctly. Breakdowns usually result in maintenance expenses and lost productivity.

capacity

A measurement of the maximum number of parts a machine of process can produce in a given period of time. The capacity of a machine or process can be impacted by time, materials, equipment, and employees.

continuous improvement

A lean manufacturing concept that describes an ongoing effort to make products, services, or processes better. Continuous improvement identifies opportunities for improvement, takes action to achieve improvement, analyzes the results, and implements workable solutions.

corrective maintenance

CM. A maintenance approach that involves performing repairs after a problem becomes apparent but before it causes failure. Corrective maintenance addresses problems before costly solutions become necessary.

cycle times

The actual time it takes a machine to perform a task and forward a product to the next step. Data about cycle times can indicate a change in a machine’s basic condition.

data

A collection of numbers, facts, and information about a process or product. Data can be created, communicated, and recorded by employees, sensors, and computers.

diverse

To come from multiple areas of expertise, in terms of both profession and lived experiences. Diverse teams should be used to troubleshoot problems and develop focused improvement strategies in order to provide insights and ideas from a wide variety of backgrounds and areas of knowledge.

downtime

A period of time when production stops, often due to mechanical failure or maintenance needs. Downtime reduces the efficiency of a manufacturing operation and should always be limited as much as possible.

early equipment management

A maintenance approach that focuses on designing, purchasing, and implementing new equipment with future maintenance needs in mind. Early equipment management is one of the eight pillars of total productive maintenance.

eight pillars

The eight principles and activities that support total productive maintenance. The eight pillars are proactive and preventive measures that improve equipment reliability and employee competence.

failures

The complete loss of performance of a component, machine, or system. Failures can render equipment unusable, cause hazardous conditions, and result in unplanned downtime.

Five S

5S. A targeted list of activities that promotes organization and efficiency within a workspace. The Five S steps are sort, set in order, sweep, standardize, and sustain.

focused improvement

A maintenance approach that attempts to improve areas in an organization that could be improved before problems can arise. Focused improvement is one of the eight pillars of total productive maintenance.

hazards

An element in the workplace that can cause injury, illness, or death. Hazards are classified by whether they are chemical, biological, physical, or ergonomic in nature.

kaizen

A method of continuous improvement that requires everyone in the company to seek and eliminate waste and error. Kaizen is a Japanese word that means “change for the better.”

lean manufacturing

An approach to manufacturing that seeks to improve quality and productivity, reduce cost, and eliminate waste. Lean manufacturing helps to eliminate waste in all its forms.

lockout/tagout

A method of protecting employees from accidental machine startup through proper locking and labeling of machines that are hazardous or under maintenance. Lockout/tagout devices include locks and keys, combination locks, energy isolating mechanisms, and warning labels.

maintenance

Any activity that contributes to the care and upkeep of machines or equipment. Maintenance approaches can involve monitoring equipment for problems or fixing a machine after it breaks down.

maintenance logs

A record of maintenance tasks. Maintenance logs contain information about who performed maintenance, when the maintenance was completed, and what specific tasks were done.

maintenance schedule

A maintenance technique that involves timing planned maintenance work, including when it should be done and who should perform it. Maintenance schedules are created as a part of implementing total productive maintenance in an organization.

Occupational Safety and Health Administration

OSHA. A government agency under the U.S. Department of Labor that sets the standards for safe working conditions in the United States. The Occupational Safety and Health Administration ensures that employees work in safe and healthy environments.

overall equipment effectiveness

OEE. A measure of how effectively equipment is being used. OEE percentage is determined by multiplying the equipment’s availability, quality, and performance percentages together.

performance

A measurement of the number of parts produced in a given in time, the speed at which they were produced, and the amount of time spent idling or stopping. Performance is calculated by dividing the number of parts produced by the capacity of parts that could be produced.

personal protective equipment

PPE. An article of clothing or a safeguarding device that employees use to prevent injury or to limit exposure to hazards in the workplace. Personal protective equipment includes safety glasses, gloves, face masks, and earplugs.

planned maintenance

A maintenance approach that is performed purposely and regularly during scheduled intervals to prevent machine deterioration or breakdown. Planned maintenance is one of the eight pillars of total productive maintenance.

planned stops

A halt in production as a result of an expected event. Planned stops may occur for planned cleaning, inspection, or scheduled maintenance.

preventive maintenance

A maintenance approach that involves regularly scheduled service and upkeep that is performed while a machine or system is still in working order. Preventive maintenance can prolong equipment life and increase production by preventing time-consuming breakdowns.

production defects

A defect created during routine production. Production defects may be a result of operator error, machine error, or incorrect machine settings.

quality

An approach to manufacturing that focuses on customer satisfaction. Quality products conform to specifications, are free of defects, and meet the requirements of their anticipated use.

quality integration

A maintenance approach that focuses on tasks that lead to the production of quality, error-free parts. Quality integration is one of the eight pillars of total productive maintenance.

quality rate

A measurement of how well products conform to specifications, are free of defects, and meet the requirements of their anticipated use. Quality rate is calculated by dividing the number of acceptable products by the total number of produced products.

reliability-centered maintenance

RCM. A maintenance approach that creates maintenance schedules for a machine or process based on its condition, environment, and frequency of use. Reliability-centered maintenance prioritizes some machines over others to create the least interruptive maintenance schedules.

root cause

The true origin of a problem, as opposed to any resulting symptoms or effects. Troubleshooting attempts to determine the root cause to create a permanent solution.

runtime

The length of time a program or process takes to execute. Runtime data is used as part of determining a machine’s availability.

Safety Data Sheets

SDS. The mandatory information that must accompany almost every chemical in the workplace. A Safety Data Sheet includes details like the risks, precautions, and first aid procedures associated with the chemical.

set in order

The step in 5S that involves organizing the workplace to ensure easy access and optimal efficiency. Set in order, or straightening, is the second step in the 5S approach.

six big losses

The areas of manufacturing where the greatest amounts of materials and time are wasted. The six big losses include planned stops, unplanned stops, small stops, slow cycles, startup defects, and production defects.

slow cycles

A period of time during which equipment is operating at a slower pace than usual. Slow cycles may be caused by old equipment or operator inexperience.

small stops

A halt in production that lasts for only a couple of minutes. Small stops are usually resolved quickly by machine operators.

sort

The step in 5S that involves separating unnecessary materials from required materials in the workplace to eliminate clutter and create additional space. Sort is the first step in the 5S approach.

standardize

The step in 5S that involves documenting and implementing methods to maintain a clean, safe, and organized workspace. Standardize is the fourth step in the 5S approach.

standards

An established policy regarding a particular practice or method. Standards created by the Occupational Safety and Health Administration are legally binding.

startup defects

A defect created at the start of production processes or after a changeover, or the time required to prepare a production for new products or work. Startup defects are either discarded or reworked into new parts.

sustain

The step in 5S that involves implementing programs and procedures to ensure the Five S steps continue to occur over time. Sustain is the fifth step in the 5S approach.

sweep

The step in 5S that involves cleaning and inspecting all areas of the work environment. Sweep is the third step in the 5S approach.

total productive maintenance

TPM. A comprehensive maintenance approach that focuses on continuous attention to the condition of production machinery and facilities. The main goal of total productive maintenance is to maximize equipment usefulness to increase production and reduce waste.

TPM

Total productive maintenance. A comprehensive maintenance approach that focuses on continuous attention to the condition of production machinery and facilities. The main goal of TPM is to maximize equipment usefulness to increase production and reduce waste.

troubleshooting

A systematic, standardized approach to solving problems quickly and efficiently. Troubleshooting focuses on identifying the root cause of a problem and eliminating that cause to create a permanent solution.

unplanned stops

A halt in production as a result of an unexpected event. Unplanned stops may occur because of equipment failure, broken parts, or understaffing.

waste

Any element of the manufacturing process that does not add value to a product, such as unused materials, lost time, or excessive inventory. The goal of lean manufacturing is to eliminate waste.

wear

The erosion of material from friction. Wear typically is caused by two or more objects in contact with one another.