Application of the hottest TPM in logistics equipm

Application of TPM in logistics equipment management

many enterprises in the world's top 500 regard TPM (total productive maintenance), that is, the productive independent maintenance activities participated by all employees, as the foundation of production and operation. The core concept of TPM has lasted for more than 30 years since it was proposed by Japanese enterprises in 1971. Enterprises have continued to promote it for decades and achieved amazing results

tpm aims to "improve the quality of the enterprise by improving the quality of people and equipment" and is based on "5S". All staff, the whole system and the whole efficiency are mobilized. All staff, from the general manager to the front-line staff, participate. Through repeated group activities, integrate the concept of equipment maintenance into the manufacturing process, eliminate unplanned equipment maintenance and solve unplanned downtime. TPM is based on group activities, Involving the whole system of the equipment, the purpose is to improve the comprehensive efficiency of the equipment. Achieve the purpose of "zero defect and zero failure" as explained by David Hummel, CEO of wiggs

tpm aims at the most effective utilization of equipment, and takes the production maintenance (PM) as the general operation system, which is composed of maintenance prevention (MP), preventive maintenance (PM), improved maintenance (CM) and post maintenance (BM). All relevant personnel, including the planning, use and maintenance of equipment, from the top management to the front-line operators, participate in the implementation of PM with independent group activities to make the loss zero

when TPM is used in the actual logistics equipment management operation, we can implement it step by step according to the following method

set up a unified equipment account

to introduce TPM into logistics equipment management, we first need to put all scattered logistics equipment under the unified management of one department (hereinafter referred to as the equipment management department), number all equipment uniformly, establish a general equipment account, and be managed by the equipment management department. According to the distribution area of equipment, the user department establishes multiple TPM activity groups, and the equipment management department guides the group activities, Group activities are carried out around the goal of TPM activities

establish a basic account at the equipment management department according to the number of each equipment, indicating the basic information of the equipment (asset number, user, use time, etc.), maintenance records, replacement of spare parts, maintenance costs, etc., so as to facilitate traceability at any time. The year-end statistics and the formulation of the next year's maintenance plan when the stiffness of the buffer remains unchanged are also supported

carry out independent equipment maintenance based on "5S"

"own equipment own maintenance". The purpose of independent maintenance is to prevent equipment deterioration. Only when the user department undertakes the "activities to prevent deterioration", the maintenance department can give full play to the real power of the full-time maintenance means it undertakes, so that the equipment can be truly and effectively maintained. The seven steps of independent maintenance are:

(1) initial cleaning: the initial cleaning is to thoroughly clean the dust and garbage centered on the equipment. Establish daily, weekly, monthly and annual maintenance system; During the cleaning inspection, problems can be found and potential defects of the equipment can be found and handled in time. At the same time, cleaning can help operators take care of the equipment

(2) difficulty improvement: in order to consolidate and improve the results of initial cleaning, it is necessary to eliminate the root causes (sources) of dust, pollution, etc. in the operating procedures of the ash impact testing machine. For this purpose, countermeasures such as elimination, capping, sealing, etc. can be taken. For the parts that are difficult to maintain, such as refueling, cleaning, decontamination, etc., effective countermeasures should also be taken to improve the maintainability of the equipment

(3) maintenance standard: according to the experience gained in the first and second steps, prepare a temporary benchmark to maintain the basic conditions of the equipment in your charge, such as cleaning, refueling, fastening and so on

(4) general point inspection: in order to give full play to the inherent functions of the equipment, it is necessary to learn the structure, function and judgment benchmark of the equipment, check the appearance of the main parts of the equipment, find and recover the defects of the equipment, and master the necessary inspection skills at the same time. Moreover, the previously prepared benchmark can be considered to be continuously improved for inspection

(5) independent spot check: on the basis of the cleaning benchmark, refueling benchmark and inspection benchmark prepared in the third step, add the content learned in the fourth step and fully comply with it, which is the independent inspection benchmark. In the process of learning and implementation, we should constantly learn and be familiar with the operation and action of the equipment, the correlation between quality and equipment, and have the ability to correctly operate the equipment and detect abnormal conditions in the early stage

(6) solidification and improvement: release the success achieved in the early stage and the formulated standards in the form of official documents, vigorously implement them, and establish a perfect maintenance and spot inspection system for equipment

(7) self management: through the activities of the first six steps, many achievements have been achieved, and the personnel have also been greatly trained. Therefore, the seventh step is to establish the awareness of continuous improvement, formulate new group activity goals suitable for yourself in combination with the company's policies and objectives, and achieve the thoroughness of self-management

repeated group activities

tpm is characterized by repeated group activities. The so-called repeating group refers to taking the grassroots group as an activity group. The leader of each group is a member of the upper level (section) group, and the section head becomes the leader of the upper level group. Similarly, the section heads are members of the higher level group, so they go up to the general manager. Through repeated group activities, we can weaken the relationship between the leader and the LED, activate the atmosphere, increase the spirit of teamwork, strengthen the communication and cooperation between groups and sections, and work together to achieve the company's goals

the purpose of group activities is to reconcile the results expected by the enterprise with the desires and pursuits of employees, so as to achieve consistency and improve the company and individuals. For the company, it helps to improve the performance of the company. For each member, it will produce a sense of satisfaction to achieve the goal and a sense of pride to realize their pursuit

the key to the success of group activities lies in having the three conditions of "working enthusiasm, working methods and workplace". Group members can independently manage their own work, that is, having working enthusiasm and working methods. Workplace includes psychological environment and physical environment. The psychological environment is to form a very harmonious environment between colleagues, superiors and subordinates, unity, friendship and mutual trust. To improve the effectiveness, stability and accuracy of physical environment testing is to form a workplace that is convenient for activities, including the implementation of "5S" activities, the environment of the workshop, the preparation and effective use of various standards and materials, the handover between shifts, and the improvement of other management systems

board management

take the group as the unit, set up a TPM activity board in each area, make the current equipment status, personnel, maintenance progress open and transparent, and urge the team members to complete the work plan according to the requirements of the group activities

group cross inspection

standardize the maintenance of equipment through monthly fixed group cross maintenance inspection to ensure that the group activity plan is completed on time; And establish a reward and punishment mechanism to ensure the authority of the inspection work and consolidate the results achieved

after TPM is introduced into the management of logistics equipment, the whole management system can be simply represented by the structure in Figure 2. This system can well solve the problems of equipment management confusion and equipment maintenance failure caused by objective reasons such as scattered logistics equipment and poor working links in the past, and can maximize the normal operation of equipment, reduce equipment failure rate and maintenance costs, and ensure the normal development of logistics business. (end)