According to experts from the Vietnam Productivity Institute (General Department of Standards, Metrology and Quality), the waste in the production process of enterprises will be significantly improved when applying TPM tool.
According to experts, waste due to redundant operations often occurs at the production site. It is any unnecessary limb movement or walking by the worker that is not tied to the production of the product.
For example, going around the workshops to find work tools or redundant movements due to poor manipulator design, inconvenient equipment – may be too high or too low…According to experts at the Vietnam Productivity Institute , redundant manipulation is a kind of waste related to people and space layout.
Along with that, waiting is the time when workers or machines are idle due to congestion or inefficient production flow. The time between each product production delay is also considered wasted waiting. Waiting significantly increases labor costs, and depreciation per unit of output is also increased. There are many reasons for waiting such as waiting for raw materials to arrive, waiting for KCS to finish checking, waiting for drawings, waiting for technical instructions, waiting for production orders, etc. These waits are the phenomenon of inconsistent management.
We often see workers waiting for the part being processed on an automatic machine until it is finished to take it out and consider it a normal thing. However, from the perspective of innovation, the question will be asked: “How to improve the steps in the process to be able to balance the line so that the number of employees is suitable for the production cycle of the company? machine?”.
Experts from the Vietnam Productivity Institute (General Department of Quality Control and Quality Control) also pointed out that waste in the production process manifests itself in many forms, such as: The maintenance department needs to buy a special spare part to repair the machine. The process goes through many stages and involved people, from the Head of Maintenance Department, Head of Technical Department, Head of Purchasing Department, Chief Accountant and Deputy Sales Director. Assuming one of the above managers is away, they have to wait, while the machine stops working, it costs money for that hour.
Or a worn jig causes the worker to recalibrate every time an item is processed, which takes time and increases costs. Machine adjustment is an activity that does not create added value, the longer the adjustment time, the more time it takes to produce, causing waste. Product inspection is necessary but does not create added value, if KCS does not check in time, the production line must stop, causing waiting and waste. Unusually damaged machinery disrupts production, causing waste. Using a machine with low total OEE efficiency is also wasteful…
So the question here is “How should management decentralize the approval of purchase requests in daily operations to be faster?” or “How to reduce adjustment time as much as possible and the better?”, “How can the worker do the post-inspection on their own without the need for a KCS or a production line?” and “Is there a way to increase OEE”?.
According to productivity experts, to solve the above waste, manufacturing enterprises should apply TPM tools. Because TPM works with the purpose of bringing high production efficiency, uninterrupted operations and work and can respond to maintenance quickly, the production and working process is more proactive, preventing prevent device failure as much as possible. Implementing TPM will create a production environment free of mechanical breakdowns and technical disturbances, demonstrating the importance of regular equipment maintenance.
TPM’s goal is to optimize the performance of machines and equipment of companies and businesses. In short, the goal that TPM aims to be summed up in “4 No” are: No machine downtime; No waste products; No loss; No accident.
Construction magazine of the Ministry of Construction | Phuong Nam | 22-06-2022