Concepts and History​

The idea of ​​Total Productive Maintenance (TPM) emerged in Japan in mid-1971 as a proposal by Seiichi Nakajima for the evolution of the Preventive Maintenance concept for a greater contribution to the Production System as a whole, from the focus on Equipment Efficiency.

At that time (1945 - 1970) the Japanese, in recovery, were forced to meet all their domestic market needs as a result of several international embargoes and adapted resources, having no other option than theories and concepts of Administration and Quality, very spread in the USA, due to its reality of high volumes, high diversity and mix of products and low capacity vis-à-vis the market.

The Toyota Production System (TPS) or Lean Manufacturing, came as a precursor to this change and the concept of Just in Time (JIT) opened a new horizon in the organization of the Supply Chain, bringing Efficiency as the basis of systemic thinking.

From this atmosphere of Waste Zero Inside, TPM emerged as a natural evolution of the thematic production of the Effective System. Among all the STP techniques, Just in Time and 5Ss are the disciplines that most contributed to the definition of the TPM pillars.

The 8 Pillars of TPM​

With a focus on Effectiveness through Safety, Loss Reduction, Resource Optimization, Productivity Increase and Quality Assurance, in addition to the 5Ss foundation, TPM generates a sense of responsibility in the entire team, from operators to high Management and it is up to business managers to be the examples in the cultural change that Lean Manufacturing requires.

1. Autonomous Maintenance
2. Focused Improvement
3. Planned Maintenance
4. Training and Education
5. Quality Maintenance
6. Initial Control
7. Safety, Health and Environment
8. TPM in the Admin

Autonomous maintenance​

It seeks the integration and collaboration of Operators in the daily routine of Maintenance, giving them autonomy to carry out preventive tasks in their work equipment, such as:

• Cleaning;

• Lubrication;

• Inspections;

This preventive work, as long as it is well recorded and analyzed, allows the identification of trends and failures in time to avoid an unplanned stop.

Focused Improvement​

It is the pillar of Continuous Improvement that uses data and maintenance history to define actions to improve Performance and Equipment Performance.

For this, it is essential that there is a culture that systematically seeks the evolution of Processes with a focus on increasing Efficiency. Approaches like Kaizen are very effective.

Planned Maintenance​

Prevention is better and cheaper than correction! This is the basis of Maintenance Planning thinking. Preventive and Corrective Maintenance were the main types of maintenance at that time and today we have Predictive, Prescriptive and Planned Corrective as an evolution of the tools and technologies that permeate maintenance.

Regardless of the different types of Planned Maintenance that exist or may exist, the idea of ​​Prevention remains intact: Guarantee the Organization's Results through the Availability of Equipment.

Currently, there are excellent Maintenance Management and Planning tools that enable greater strategic results for the Maintenance area.

https://sequormtc.com.br/ is the best solution on the market for Maintenance Planning, Management and Execution.

Training and Education​

As with all Lean philosophy, TPM also practices people development and discipline as a foundation for success. People are the basis of any business, whether as a Customer or Supplier, and keeping them motivated, involved and engaged is essential for the processes to function fully.

• Training operators and developing them in Autonomous Maintenance will create a strong bond with respect to the business objectives and Customer success;

• Training and developing maintenance personnel will improve maintenance techniques and plans;

• Train Managers to be mentors and responsible for keeping the TPM culture in progress;

• Creating a knowledge base based on Maintenance data is essential to optimize knowledge sharing;

Quality Maintenance​

It is the approach of Total Quality in the scope of Maintenance, applying tools for problem solving and continuous improvement such as MASP, PDCA, Ishikawa... allow the reduction of errors, failures and waste. In addition to eliminating waste, reducing the variability of mapped parameters that directly interferes with the availability of equipment is essential and this is where Six Sigma tools come in.

Initial Control​

The integrated action between Maintenance and Industrial Engineering is very important to start maintenance planning while still in the equipment design phase. The knowledge base already acquired by TPM is a source for the Initial Control of new equipment.

Failure Mode Effect Analysis (FMEA) is an excellent example of how to apply Initial Control to new equipment.

Administrative TPM​

It consists of applying all the concepts of Lean Manufacturing and TPM in the administrative sphere. Applying the concepts for the elimination of waste, engagement, quality and efficiency. Agile Management concepts have a strong connection with this pillar.

Safety, Hygiene and Environment​

Safety first is a pillar of TPM. Maintenance plans must start with the Preliminary Risk Analysis, Work Permit and Work Release, to ensure that everyone involved is safe with risks mapped and mitigated.

Analysis of Environmental Aspects and Impacts generate awareness and concern for the environment during maintenance work, from acquisition to disposal and destination of inputs and their waste.

A healthy and comfortable work environment increases employee productivity, well-being and engagement.

Maintenance Excellence​

It is a great honor to be part of the construction of such a valuable Product for the Market, for both Industrial customers and Service Provider customers:

Sequor MTC​

The name MTC originated in 2018 at Snef Groupe's global leadership meetings on the theme Digital Transformation, where our CEO Stéphane Corteel motivated us to develop a Total Maintenance Control solution to boost and improve the lives of our customers! This is how Sequor Maintenance Total Control, our successful Sequor MTC, was born! Since then, many customers have improved their processes, many ideas and solutions were implemented and improved, always focusing on market needs through collaborative research and immersion with Clients and partners, making Sequor MTC a powerful ally for the improvement and increase of Gain for any process. The Sequor team counts on specialists with great experience in the area, who worked in Maintenance Management and Execution in multinational companies from various segments from Energy Measurement, up to the Automotive sector, through Services and Transformation Industry... making Sequor's know-how a unique feature in the market. Meet Sequor MTC and make your process constantly evolve!

How the lack of maintenance planning affects the productivity and competitiveness of the industry​

Total Productive Maintenance (TPM) came as the watershed for understanding the influence of maintenance on the profitability of an operation. The availability of assets is an essential matter for the flow of value in the supply chain, from manufacturing to delivery of the product or service to the Customer.

Long before any science about Processes or Maintenance, we have already heard from popular culture that "Prevention is better than Cure", and it is not that this maxim is true, so much so that since the Second Generation of Maintenance in the mid 1950's, starting in the USA and spreading and evolving in Japan within the Lean Philosophy, the concept of Preventive Maintenance emerges, becoming in 1970 the state of the art that we know as Total Productive Maintenance (TPM).

The Sequor MTC and Maintenance Generations​

This philosophy brings the concept of Planning as one of the Pillars of Effectiveness in maintenance, directly correlating Machine Availability with the Profitability of a productive operation. Since then, the understanding that Maintenance is essential to sustain a business is increasingly widespread, but unfortunately, it is still not unanimous. As consultants and solution developers, we still face ineffective processes mainly due to serious planning failures, where Corrective / Reactive intervention is the main approach. This ends up triggering classic waste already mentioned in the First Generation of maintenance (1940), such as:

• Movement - Not having the necessary resources at the exact time and place, resulting in loss of time and efficiency eg Tools, Human Resources, Materials...
• Processing - Not having the planning of what and how to do, generating quality and reliability losses, leading us to the next waste:
• Correction - Without planning, "doing it right" the first time is very difficult and this generates several problems, but mainly, those that compromise the asset's performance over time.

Other topics are extremely relevant for a Maintenance of Excellence in the journey of Digital Transformation of Processes. Reliability and Asset Management are key!

The RCM Concept - Reliability Centered Maintenance or Reliability Centered Maintenance according to NBR-5462 standard, is understood as the percentage or probability of adequate functioning, within a certain period of time, of machines, systems and/or items inserted in the production chain.

This monitoring is done through historical data on the performance of the equipment and its qualitative estimate of future operation.

Thus, it is possible to determine, for example, what percentage of chance an Electric Motor will operate, according to its specifications, in the next 10,000 hours.

When it comes to Reliability, it is essential to apply tools such as the FMEA - Failure Mode Effects Analysis, so that the equipment is "broken" in Functions, Systems, Components... and then individually evaluated as to the potential Failure Modes, Effects, Occurrence, Severity and Detection, generating a Risk Priority Index (NPR). The NPR is the basis for defining Priority and Criticality for the Maintenance Plan.

The discipline of Corporate Asset Management (EAM) is an increasingly present reality in the daily lives of maintainers, since IIoT and Cloud Computing technologies constantly evolve at a speed that enables large-scale application. In this way, automation and data reception in real time allow for an efficiency management never seen before.

Desde a gestão de ciclo de vida de um ativo e sua performance diária, até Data Analytics e Configuração Avançada de Dispositivos, a Gestão de Performance do Ativo (APM) permite a Predição e Prescrição para os sistemas de Manutenção trazendo efetividade e aumento de disponibilidade do equipamento.

From managing the lifecycle of an asset and its daily performance, to Data Analytics and Advanced Device Configuration, Asset Performance Management (APM) enables Prediction and Prescription for Maintenance systems, bringing effectiveness and increased availability of the equipment.

How to solve and improve your process​

With years of practical experience in Maintenance Management and with a focus on collaboration and research with Customers and Partners, Sequor brings a complete solution for Planning and Execution of Maintenance with Mobility and Effectiveness.

The Sequor Planner, as a Pillar of the Planning / Prevention TPM, consolidates all generated orders into a powerful Tool, either through the Recurrence Plan, or via the creation of individual orders. Power your analysis graphically and dynamically with functions such as Drag&Drop, release for Mobile Execution by batch, fine adjustments of up to 15 minutes directly in the Calendar component and much more.

Autonomous maintenance is also another pillar of TPM supported by Sequor MTC, allowing, through the Recurrence Plan, to create daily verification events for Operators and Equipment Sponsors to carry out through mobile, thus allowing for better management of the health of the Asset.

Sequor MTC has a great differential in Mobile Execution that, in a clear and objective way, leads the Maintainer on an effective journey and without waste, whether of time, materials or environmental impacts. Your Maintenance will have excellent results with Sequor MTC!