Applying the TPM improvement plan

This chapter presents an example of a total productive maintenance (TPM) improvement plan training exercise that was part of a four-day TPM facilitator-training course. This exercise was introduced in a company named “Merlin Gun Technology.” Merlin Gun Technology has the following characteristics: the company makes welding guns and welding tips; most of the volume is in welding tips; the company experiences pressure from customers to produce in small batches; the company is expanding into further export markets; and department 50 is recognized as the main bottleneck. The team consisted of three production personnel (one per shift) and two maintenance personnel (one electrical and one mechanical). The output of this particular exercise is based on a one-hour feedback presentation, which the five budding TPM facilitators made after spending two and a half days assimilating and using the nine-step TPM improvement plan. It was concluded that to achieve world-class performance, the company must move forward to achieve a total quality process; satisfy customer requirements; consider all internal and external factors; and meet internal customers and suppliers and agree on requirements.