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TPM Equipment Management Series: Six Sources of Improvement

2019-08-15View Original

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In the TPM equipment management series: Six Sources of Improvement. Applying the improvement methods and fundamental theories derived from scientific research in TPM management not only helps to ensure product quality, eliminate waste in key processes, reduce risk factors, lower the rate of rework, control costs, and improve the working environment; more importantly, TPM management can **increase productivity**. “The application of the \"Six Sources\" improvement in companies has yielded significant benefits. I. Proper identification of the six sources 1. Pollution sources: namely, the origins of dust, oil stains, waste, and scraps from production materials. 2. Sources of difficult cleaning: Sources of difficult cleaning refer to locations that cannot be cleaned. 3. Fault sources: Common fault sources refer to the potential factors that cause common faults. 4. Sources of waste: Excessive waste occurring during the production process. 5. Defect sources: namely, the flaws that arise from manufacturing processes that compromise product quality as well as those that occur during the processing stage. 6. Risk sources: Risk sources refer to potential origins of common failures. II. How to carry out six-source improvement 1. Addressing pollution sources There are three key aspects to controlling pollutants: one is to address the root causes, and the other two are to prevent the spread of environmental pollution ; Third is the collection and recycling of air pollutants. The most common method for dealing with pollutants during cleaning is to use various cleaning techniques, which depend on the specific machinery and equipment; different cleaning methods are designed accordingly. For example, air compression can be used for cleaning, and industrial vacuum cleaners can be employed extensively to prevent dust from spreading ; For some machinery and equipment, their locations need to be cleaned by scrubbing, and depending on the type of equipment, the tools used for scrubbing can vary as well. 2. Resolution of sources causing cleaning difficulties: Addressing these difficult-to-clean areas also involves three approaches. First, it is necessary to control the root causes so that such areas cannot become polluted ; Second, develop specialized cleaning tools to turn tasks that were impossible to complete into ones that are very easy to handle ; Third is the water barrier for air pollutants and their recycling. 3. Resolution of fault sources: The key to dealing with common fault sources lies in understanding the conditions that give rise to these faults, and then using certain methods to prevent or suppress the occurrence or progression of such conditions. If common faults occur, it is necessary to analyze and understand the patterns and causes behind them, then take effective measures to prevent them from happening. Subsequently, based on those patterns and causes, practical solutions should be found and put into practice. 4. Addressing sources of waste: To deal with sources of extravagant waste, it is necessary to take thorough action at the source where they originate. Things like lights remaining on after people leave, central air conditioning not being turned off, and equipment continuing to operate ; There are various forms of waste caused by leaks, such as water seepage, steam leakage, oil leakage, and leakage of other substances. Various methods must be employed to carry out leak sealing and repair work; if it is indeed impossible to stop the leaks, then efforts should be made to recycle and reuse the leaked materials ; To address the excessive waste of raw materials, efforts are made not only to save materials through improvements in processing techniques and design concepts, but also to make significant efforts in restoring and reusing waste materials. 5. Resolution of defect sources: To address the issues related to defect sources, it is necessary to start by examining the most fundamental causes, such as the machines and equipment themselves, as well as the way employees operate them and the standards for maintenance. Only in this way can various difficulties be resolved. 6. Resolution of hazard sources: The handling of hazard sources depends on an analysis of the immediate environment to identify unsound environmental factors. These are addressed through methods such as reorganizing the layout, upgrading the environment, redesigning it, installing additional safety equipment, and implementing systematic organization at the site. Human factors that contribute to hazard sources are mitigated and prevented through standardized training and strict requirements, as well as through visual monitoring. “The “six sources” problem represents a key challenge, a difficult issue, and a blind spot in the maintenance of TPM equipment. To address it effectively, all personnel need to be involved throughout the process, with thorough attention to every detail, in order to create a positive atmosphere and foster good habits. It is important to ensure that the work related to the “six sources” is closely linked to daily tasks and integrated with efforts to save energy and reduce emissions; it must not be a mere formality without real substance.

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