Total Productive Maintenance and Frescura Quality, an inseparable pair
 
The philosophy upon which this methodology is based has its origins in a very simple principle: if the production system is functioning perfectly, with zero losses, the company manages to achieve its goals more easily. Therefore, the only true aim of TPM is to increase production.
Before introducing the techniques inherent to the TPS and to Total Quality, we were still adhering (indeed, just like the majority of companies) to the 1950s concept of maintenance, known as breakdown maintenance. Obviously, this type of approach left things completely to the random course of events.

Then the Toyota Production System arrived with its TPM

Total Productive Maintenance
Accepting the idea that our system was preventing us from achieving the ambitious goals in terms of quality that we had set ourselves, with the introduction of Total Productive Maintenance and the methodologies derived from it, we made an enormous leap forward, moving rather quickly from the concept of breakdown maintenance to systems which currently guide the management of our production, thereby achieving the capacity to manage complex preventative maintenance, only then to quickly make the transition to the concept of productive maintenance, and finally to reach corrective maintenance.

The TPM structure
In its general set-up, TPM is structured into seven main points; the seven pillars upon which the entire methodology rests:
Specific improvement of machines;

1. Autonomous maintenance;
2. Planned maintenance;
3. Education and training;
4. Managing the start-up of the systems;
5. Quality maintenance;
6. Managing safety and environment.

TPM and the six major losses
By using TPM in Frescura, we have concentrated upon tackling the six major losses identified by the Toyota Production System:

1. stops for unexpected failures;
2. set-up times;
3. system speed lower than standard;
4. losses for production waste and reworks;
5. start-up losses.

Autonomous Maintenance
A great result achieved by implementing TPM was a real jump in the quality of system care by involving operators in taking personal care of their machines (autonomous maintenance):

• daily system inspection;
• cleaning of machinery;
• lubrication,
• micro-repairs;
• early detection of anomalies;
• noticing defects at the first sign.

The Added Value of TPM
The advantages gained by Frescura by implementing TPM are huge:

• high system efficiency;
• preventative maintenance;
• autonomous system management;
• increase in system productivity
• higher product quality.