TPM Solutions
IFGS accompanies the client through the journey of TPM implementation whether by consultancy or training.
IFGS follows the globally recognized standards of JIPM (Japanese Institute for Plant Maintenance), and customize the program structure to fit factory needs.
TPM identifies and then seeks to eliminate all major equipment and process wastes and losses by involving and utilizing all company resources, which has very positive impact on Overall Equipment Efficiency.
IFGS guides client through his implementation journey, step by step, of TPM 8 Pillars. TPM solutions include:
One of the basics of professional maintenance system is to have a well-designed work flow and reporting system for maintenance department, such as:
- Problems reporting, analysis and documentation.
- Communication plan between production and maintenance
- Developing performance measures for maintenance function
- Developing performance measures for equipment
- Enhanced work flow for maintenance planner/ purchasing to release purchasing orders for suppliers
Translating maintenance plan into spare parts requirements, and then to inventory management strategy is an important issue for any factory to avoid stock out and over stocks. Precise Spare parts management, not only include inventory management, but also includes parts coding and warehouse arrangements and ordering process simplification.
Equipment description and breakdown structure is a pre-requirement for many later steps in TPM or professional maintenance management, such as spare parts inventory management, failures analysis, maintenance plans and technical trainings.
Every Equipment should be coded, prioritized and described as a tree of assembly, sub-assembly and components, then every part will be described technically and drawn if needed.
Autonomous maintenance in implemented through 7 steps, to return machine to its basic condition and eliminate sources of forced and accelerated deterioration. Autonomous maintenance is the beginning of handing over some technical tasks to machine operators (including cleaning, inspection and lubrication), in order to free up a portion of maintenance team time to do more advanced tasks regarding machine improvement.
Setting proper maintenance strategy for every equipment comes after precise analysis for the situation, it requires accurate data collection and qualified staff for interpretation. Maintenance calendar may include time-based maintenance, condition-based maintenance, or periodic measures.
5S is the foundation of any improvement initiative, it’s a Japanese tool to organize and standardize workplaces. 5S stands for sorting, straighten, shine, standardize and sustain.
Visual Management Boards is a visual communication tool, used to communicate performance measures, targets, One-point lessons (OPL) and plans.
One of the main reasons of machine accelerated deterioration is poor or improper maintenance activities. Safe working procedures (SWP) is a tool to standardize and transfer the procedure of maintenance and technical tasks.
If there are many ways to do the job, standardization is the tool that communicate the best way that ensure best quality, lowest cost and higher delivery performance. Standard operating procedure to be done for all operational tasks to ensure process efficiency and safety for labor and machine.