TPM Transformation

Do you have an effective Equipment Management Strategy to minimise the Life Cycle Cost of your Plant & Equipment?

TPM Transformation

by Ross Kennedy, 4 April 2019

Do you have an effective Equipment Management Strategy to minimise the Life Cycle Cost of your Plant & Equipment?

If your Operational Performance is dependent on Plant & Equipment performance, then having an effective Equipment Management Strategy focused on minimising Life Cycle Cost should be a high priority. Too often, Senior Management leave it to the Maintenance or Engineering Manager to ‘look after the Plant & Equipment’ rather than recognising the importance of making it a business imperative involving everyone. This is where TPM – originally called Total Productive Maintenance, however more appropriately renamed Total Productive Manufacturing or Total Productive Mining comes in.

We hear all about Lean transformations, however what is missing is the recognition that TPM, if properly understood, measured and implemented, is a plant & equipment transformation based on Prevention at Source which is the same thinking that initiated the development of the Toyota Production System and Lean.

If you are buying new plant & equipment, operating plant & equipment, or maintaining plant & equipment, TPM applied as an Equipment Management Transformation is the most cost effective Equipment Management Strategy that will minimise the Life Cycle Cost of your plant & equipment.

So what do we mean by an Equipment Management Transformation?

Applying Prevention at Source for equipment involves identifying, at the earliest possible time, the small little equipment defects such as bent or damaged grease lines impacting on proper lubrication, which leads to rotating parts accelerating their deterioration resulting in the need for early replacement and higher Life Cycle Cost.

If your Plant & Equipment is Operator dependent on performance such as packaging or bottling lines, as opposed to trains, planes or nuclear power plants, the best people to identify the small little equipment defects are the Operators. However, to introduce this you need to transform traditional thinking so that you can:

  • Create time to develop all your people by improving Overall Equipment Effectiveness so as to make more good output in less time;
  • Train all the Operators to know what to look for to find equipment defects and problems;
  • Change the equipment so it is easy for Operators to find the equipment defects or problems;
  • Create a maintenance support capability that can respond to small equipment defects or problems identified by Operators rather than rely solely on traditional work order priorities; and
  • Stabilise the Production Plan to ensure regular Clean for Inspections by Operators supported by Maintenance, in order to develop the Prevention at Source skills of your Operators and Maintainers.

Why not start your Equipment Management Transformation today!

If you would like to learn more about Australasian TPM and undertaking an Equipment Management Transformation contact myself Ross Kennedy at