TPM (Total Production and Maintenance) management system of the eight pillars of self-preservation

In today's competitive manufacturing environment, the efficient and stable operation of equipment is critical to the productivity and product quality of enterprises. The TPM (Total Production Maintenance) management system came into being, in which self-preservation plays a pivotal role as the primary pillar. As the first of the eight pillars, it is not only the soul of TPM activities, but also a key way for enterprises to achieve efficient operation of equipment, reduce maintenance costs, and enhance overall competitiveness. The core of the concept of self-maintenance lies in "self-maintenance of their own equipment", which is not only a practice at the operational level, but also a management philosophy that goes deep into the bone marrow, leading the enterprise to a higher level of equipment management.

1. The meaning and value of self-preservation

In modern industrial production, equipment is the material basis of enterprise production activities, and its operation status is directly related to production efficiency, product quality and even the economic benefits of enterprises. However, traditional equipment management often relies on professional maintenance personnel to repair equipment when it fails, which is not only costly, but also easy to affect the production schedule. The proposal of self-preservation is to break this dilemma, and to realize the daily maintenance and preventive maintenance of the equipment by cultivating the equipment maintenance awareness and ability of the operators, so as to effectively prevent the deterioration of the equipment, prolong the service life of the equipment, and ensure the continuity and stability of production activities.

The value of self-preservation is not only reflected in the material level, but also in the improvement of corporate culture and employee quality. It emphasizes the initiative and sense of responsibility of employees, encourages employees to regard the equipment as their "partner", and establishes a deep emotional connection with the equipment through daily maintenance activities such as cleaning, inspection, fastening, lubrication, etc. This emotional connection further stimulates the enthusiasm and creativity of employees, promotes unity and cooperation among employees, and creates a positive working atmosphere for the company.

2. Seven steps for self-preservation

The implementation of self-preservation is not achieved overnight, but needs to be progressed gradually through a series of systematic and orderly steps. With the operation department as the core, it unfolds gradually through rigorous and meticulous seven steps, like a well-choreographed symphony, with every note in place, and together play a magnificent movement of equipment maintenance. Specifically, the seven steps include:

Step 1: Initial cleaning

Initial cleaning is the starting point for self-preservation and an important part of discovering potential problems with equipment. Employees need to thoroughly clean the equipment, including the surfaces, internal structure, and surrounding environment. During the cleaning process, employees not only remove dust and debris, but more importantly, through observation and touch, find abnormal conditions such as wear and tear, looseness, leakage and other equipment of the equipment. For example, when cleaning a machine, you may find signs of tool wear, insufficient lubrication of the rails, or loosening of the electrical wiring.

Key takeaways:

Develop a detailed cleaning plan and clarify the area to be cleaned and who is responsible.

Train employees to clean up with an "eye for finding problems".

Step 2: Countermeasures to the source of occurrence and the difficult part

After the initial cleaning is completed, it is necessary to find out the source and difficult parts of the equipment according to the problems found, and formulate corresponding countermeasures, such as improving the equipment design and adding protective devices, so as to reduce the difficulty and frequency of cleaning. Sources are the root causes of problems such as contamination, leaks, breakdowns, etc., while difficult areas are places that are difficult to clean, inspect, and maintain. For example, for a piece of equipment that frequently leaks oil, it is necessary to find out the source of the oil leakage and take measures such as sealing improvement and oil pipe replacement. For corners that are difficult to clean, special tools can be designed or the equipment structure can be improved.

Key takeaways:

Conduct an in-depth cause analysis to identify the root cause.

We will work with relevant departments to develop effective countermeasures.

Step 3: Establish provisional benchmarks for self-preservation

In order to ensure that the daily maintenance of the equipment can be carried out in a standardized manner, it is necessary to establish temporary self-maintenance standards. These benchmarks not only provide employees with a clear basis for operation, but also provide a traceable record of subsequent maintenance activities. This is the "operation manual" established for equipment maintenance, which clarifies the standards and cycles of daily cleaning, inspection, tightening, lubrication and other maintenance activities, so that operators can carry out maintenance work in an orderly manner. For example, it is stipulated that the appearance of the equipment should be cleaned every day before starting, and the key parts of the equipment should be lubricated every week.

Key takeaways:

Benchmarks should be simple and straightforward, easy for employees to understand and enforce.

According to the actual operation of the equipment, the benchmark is continuously optimized.

Step 4: Total inspection

The total inspection is a comprehensive inspection and evaluation of all parts of the equipment, including mechanical, electrical, instrumentation, etc. Through the general inspection, employees can understand the structure and working principle of the equipment, grasp the normal status and abnormal performance of the equipment, find potential problems of the equipment in time, and provide a basis for subsequent maintenance and improvement. When conducting a total inspection, it is necessary to use professional testing tools and methods, such as thermometers, vibration analyzers, etc.

Key takeaways:

Compile a detailed general inspection manual, and clarify the items and methods of inspection.

Carry out professional training for employees to improve their inspection skills.

Step 5: Autonomous inspection

After mastering the knowledge and skills of total inspection, employees can conduct independent inspection. Autonomous inspection is to self-inspect equipment in daily work in accordance with established benchmarks and methods, and find and deal with problems in a timely manner. Through independent spot checks, the maintenance of equipment can be integrated into daily production and a normalized management mechanism can be formed.

Key takeaways:

Establish an effective supervision and feedback mechanism to ensure the quality of self-inspection.

Encourage employees to put forward suggestions for improvement and constantly improve the inspection system.

Step 6: Standardization

Standardize all aspects of self-preservation work, including operating procedures, standards, records, etc. Standardization can ensure the consistency and stability of work, improve work efficiency and quality. For example, the standard operating procedures for equipment cleaning are formulated, and the sequence, tools and methods of cleaning are specified; Establish a standard process for equipment troubleshooting, and clarify the procedures for reporting, maintenance, and acceptance.

Key takeaways:

Combined with the quality management system, to ensure the scientific and effective standards.

Regularly review and update the standard to adapt to the needs of equipment changes and management.

Step 7: Thorough self-management

Through continuous training and education, improve the awareness and ability of employees' self-management, so that employees can consciously comply with various standards and systems, and actively participate in the management and improvement of equipment. At the same time, establish a good teamwork atmosphere to promote experience exchange and knowledge sharing among employees.

Key takeaways:

Establish an incentive mechanism to commend and reward outstanding employees.

Regularly carry out summaries and evaluations of self-preservation, and continuously promote the in-depth development of work.

The Seven Steps of Self-Preservation are an interrelated and step-by-step process. By conscientiously implementing each step, enterprises can give full play to the enthusiasm and creativity of employees, improve the overall efficiency of equipment, reduce production costs, and enhance the competitiveness of enterprises. Let us take active action, integrate the concept and method of self-preservation into our daily work, and contribute our own strength to the development of the enterprise!

3. The core of self-preservation

The core of self-maintenance is to prevent equipment deterioration. Through daily cleaning, inspection, tightening, lubrication and other maintenance activities, the equipment can always be kept in the best condition, reducing downtime and improving production efficiency. Imagine a piece of equipment that breaks down frequently due to a long-term lack of maintenance, which not only affects the production schedule, but also increases the cost of repairs and reduces the quality of the product. These problems can be effectively solved through self-preservation.

Fourth, the meaning of self-preservation

The significance of self-preservation is not only to reduce the burden of professional maintenance personnel, but more importantly, to cultivate the awareness and ability of equipment maintenance of operators. In the past, operators may have thought that equipment maintenance was the responsibility of the service personnel and that they were only responsible for the operation. However, this concept has undergone a fundamental change with the promotion of self-preservation. From "I want to maintain" to "I want to maintain", the operator gradually realizes that he is the owner of the equipment and is directly responsible for the performance and status of the equipment.

For example, before the implementation of self-maintenance, the equipment failure rate of a manufacturing company remained high, and production was often interrupted due to equipment failure. However, since the introduction of the concept of self-preservation and the training and practice of self-maintenance methods and skills have been mastered by operators, the equipment failure rate has been greatly reduced and the production efficiency has been significantly improved. Operators can not only find and deal with small problems in time, but also provide accurate fault information for professional maintenance personnel, which greatly shortens the maintenance time.

In another company, the introduction of self-preservation also promoted teamwork and communication among employees. In the process of equipment maintenance, operators share experience and skills with each other to solve problems encountered. This team atmosphere not only improves the effectiveness of equipment maintenance, but also enhances the sense of belonging and cohesion of employees.

In short, as the primary pillar of the TPM management system, self-preservation brings new ideas and methods to the equipment management of enterprises. It cultivates the self-management awareness and ability of employees, realizes the efficient operation of equipment, and lays a solid foundation for the sustainable development of the enterprise. In the future development of the manufacturing industry, self-preservation will play a more important role, leading enterprises to a higher level of production efficiency and quality.