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As I mention before in my previous Total Productive Maintenance article, there are 7 main factors that contribute to machines breakdown. In this article I would like to share how this can be minimized. In Total Productive Maintenance there 5 main agenda or actions that put into focus in order to ensure the machines arerunning as required. The 5 main actions that I will explain are most likely will help to prevent from major breakdown. These actions are involving with basic maintenance, skill and early stage of machine development (design stage).

1. To ensure that the machines are running at high efficiency, basic maintenance is the mot important. We can see this easy by looking our car periodical maintenance as an example. In car maintenance we normally clean our car, change the engine oil periodically and check for any looseness or scratches. This is basic since this activities can be done by ourselves or owner of the car. So for machine maintenance it is almost the same. Where the owner of the machine which most likely the operator as the same as owner of the car shall performs the basic maintenance as the car. Three basic maintenance activities that are perform a cleaning, fill up or change the lubrication and check for any looseness (looseness could cause vibration and it is dangerous). The 3 activities are the foundation of preventive maintenance.
2. Periodical machines inspection and basic activities must be performed with care and deeply detail. It can be performed every day in the morning before start operating. In order this activities are well performed a document such as check sheet and schedule are necessary. Beside daily inspection or basic activities, there are also long periodical maintenance that are done monthly and yearly. It normally performed by qualified or high skill person in addition by a Factory Maintenance section. It sometimes need a high technology tool. It also shall have document to monitor and manage the activities. Now a days a systems called Computerized Maintenance Management Systems (CMMS) software has been widely used to manage such activities. Today there a lots of CMMS software for us to choose.
3. Protect the machines from dirt and unwanted material that could cause fatal to it. As mention above, cleaning is very important to eliminate the unwanted material but there some areas that required severe attention and need frequent cleaning. This areas are most likely to be very sensitive to the unwanted material. So an improvement or kaizen are required to ensure the areas are protected. A good cover or sheild is a good start to protect these areas. With the cover or shield it also will protect the operator from unsafe condition.
4. Minimized the machine weaknesses during design stage. It is important that for new machines, all sections should discussed and informed any weaknesses from current machines so that it shall be eliminated to new machines.
5. Skill up for both operator and maintenance personnel. Low skill to the operator could bring to miss-operation and could contribute to machine accident. For your information once a machine involve in accident it is very hard to return to original performance so it is bad for long term operation. Miss-judgment of machine abnormality and miss-replace the correct part to machines are the weakness of maintenance personnel that must be avoided. If this happen the repair time will become longer and will delay the repair schedule.

There are 5 actions required to ensure the machines are operating at optimum. When the 5 actions are performed at very best, operation rate shall be at the best everyday. In Total Productive Maintenance piller this is the foundation to ensure high productivity and low rejection of product.