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نگهداری و تعمیرات بهره‌ ور فراگیر TPM

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نگهداری و تعمیرات بهره‌ ور فراگیر TPM


بدون شک یکی از چالش‌های صنایع و سازمان­‌ها تعاملات بین واحدهای درگیر در سازمان به خصوص واحدهای نگهداشت و بهره برداری است. سازمان‌ها همواره به دنبال افزایش بهره‌وری تعاملات افراد در سازمان­‌های خود هستند. بدون شک نگهداری و تعمیرات بهره ور فراگیر Total Productive Maintenance(TPM) یکی از راهکارهای افزایش سطح کارتیمی در سازمان است. TPM یک فرهنگ جامع است که از طریق درگیر کردن تمامی افرادی که (به طور مستقیم یا غیر مستقیم) به نحوی با تجهیزات سازمان در ارتباط اند، سعی در افزایش مسئولیت پذیری و کاهش ضایعات (اتلاف‌های زمانی، کاهش کیفیت و…) دارد.

اجرای TPMمی‌تواند تاثیر شگرفی بر روی بهره‌وری افراد و سازمان داشته باشد و آن سازمان را به یک سازمان پویا، بهره‌ور، ایده پرداز و مقاوم در برابر تهدیدات برون سازمانی تبدیل کند البته به شرط آنکه درست و به موقع اجرا شود. در ادامه به اهداف TPM اصول آن و اینکه برای چه سازمانی و درچه شرایطی می‌تواند مفید باشد می‌پردازیم.

اهداف نگهداری و تعمیرات بهره ور فراگیر TPM

همانطور که پیش‌تر گفته شد TPM رویکردی است که کل افراد سازمان را درگیر می­‌کند بنابراین هدف آن نیز روی کل سازمان تاثیر می‌‌گذارد. منظور از کلمه Total در Total Productive Maintenance در واقع به سه مفهموم اشاره می‌کند:

  • اول منظور اثر بخشی فراگیر است که به توسعه و بهبود راندمان اقتصادی در تمام ابعاد سازمان و واحدها منجر می‌شود.
  • دوم پیشگیری فراگیر است که به جلوگیری از خرابی، حوادث، ایجاد ضایعات و تبعات حاصل از آن‌ها توجه می‌کند.
  • سوم همکاری و اشتراک مساعی است که به درگیر بودن و تاثیر همه افراد سازمان دلالت دارد.

اجرای درست و به موقع TPM در سازمان می‌تواند منافع زیر را برای سازمان به ارمغان بیاورد:

  • کاهش توقفات تجهیزات و افزایش تولید
  • کاهش ضایعات تولیدی
  • بهبود تعاملات بین افراد مختلف سازمان
  • بهبود فرایندهای سازمان
  • رضایت‌مندی مشتری
  • افزایش انگیزه و روحیه افراد
  • افزایش بهره‌وری سازمان
  • کاهش حوادث و افزایش ایمنی
  • …

ارکان اصلی اجرای نگهداری و تعمیرات بهره ور فراگیر

  • نظام آراستگی محیط کار 5s

در هر سازمانی که نیاز به اجرای نگهداری و تعمیرات بهره ور فراگیر TPM باشد، در گام اول نیاز است یک خانه تکانی اساسی انجام شود. وقتی محیط کار تمیز نباشد مشکلات و ریشه‌های آن‌ها دیده نمی‌شود. انجام نظام آراستگی 5S کمک می­‌کند تا محیط کار تمیز و مرتب شود و اقلام ضروری و غیر ضروی برای انجام کار مشخص و جانمایی شود و نظم استفاده و قرار دادن ابزار و تجهیزات مورد نیاز در هرکجای سازمان به یک فرهنگ تبدیل شود. این گام مهم‌ترین گام پیاده سازی نت بهره ور فراگیر است و اجرای موفق آن به میزان قابل توجهی در موفقیت پیاده سازی نت بهره ور فراگیر TPM نقش دارد.

  • بهبود مستمر (کایزن)

در TPM این اعتقاد وجود دارد که بهبود در ابعاد مختلف سازمان هرچند کوچک باید به طور مستمر وجود داشته باشد. بهبود مستمر با رویکرد کایزن معمولا به سرمایه‌گذاری زیادی احتیاج ندارد و اساس آن این است که تعداد بسیار بیشتر بهبود کوچک که به مرور ایجاد شود اثربخش‌تر از چند بهبود بزرگ در یک سازمان است. زیرا این بهبودها فرهنگ سازمان را می‌سازند و سازمان را پیوسته پویا نگه می‌دارند.

  • اجرای نت خودکنترلی توسط پرسنل تولید و بهره‌برداران

نت اپراتوری یا نت خود کنترلی به فعالیت‌هایی می‌پردازد که بایستی توسط اپراتور و کارکنان بهره‌بردار و در راستای نگهداری از تجهیزات انجام گردد. این مجموعه فعالیت‌ها با تکیه‌بر نیروی انسانی و رشد و ارتقاء فرهنگ و مهارت‌های آنان سعی در کاهش و حذف ضایعاتی همچون عیوب کیفی، خرابی‌های اضطراری و حوادث از صنعت دارد.

  • اجرای نگهداری و تعمیرات پیشگیرانه توسط واحد نگهداشت سازمان

نگهداری و تعمیرات پیشگیرانه به دنبال جلوگیری از توقفات ناگهانی تجهیزات به کمک تعریف اقداماتی برای شناسایی و پیشگیری از خرابی است. این سیاست نگهداشت، رفته رفته سازمان را از یک سازمان واکنشی که وقتی خرابی اتفاق می‌افتد و تولید متوقف می‌شود به دنبال راه حل می‌گردد، به یک سازمان پیش‌کنشی که از قبل می‌تواند خرابی‌ها را پیش‌بینی و پیشگیری کند، تبدیل می‌­کند.

  • آموزش مستمر مفاهیم به کلیه‌ی پرسنل

تکرار تکرار، معجزه. این اغراق نیست. اگر بخواهیم به اهداف ذکر شده در TPM برسیم باید آموزش ببینیم و این آموزش باید به صورت مستمر باشد. آموزشی وقتی می‌تواند مفید و موثر باشد که از آن آموخته‌ها بازخورد گرفته شود و برمبنای بازخوردها آموزش‌های بعدی تکرار و یا تعریف شود تا بهبود و ارتقا افراد اتفاق بیافتد. هدف اصلی از آموزش نگهداری و تعمیرات بهره ور فراگیر TPM تربیت پرسنلی (با تمرکز بر پرسنل بهره بردار و تولید) چند مهارته است که بتواند متناسب با چهارچوب وظایف خود تصمیم بگیرد.

  • حفظ و مدیریت کیفیت محصول

همه‌ آنچه گفت شد انجام می‌شود تا در نهایت رضایت مشتری جلب شود. اگر این اتفاق نیفتد، یعنی بهره‌وری و سودآروی سازمان که هدف اصلی TPM است محقق نشده است. این رکن اساسی از TPM، با تمرکز بر روی حذف ناسازگاری‌ها و سیستماتیک کردن فرایندها سعی در کاهش ضایعات و افزایش کفیت و رضایت مشتری دارد. در واقع نگهداری و تعمیرات بهره ور فراگیر TPM بر روی این بخش تمرکز می­‌کند تا ببیند کدام قسمت‌ها از فرایند تولید بر روی کیفیت بیشترین تاثیر را می­‌گذارند و سعی می‌کند آن‌ها را بهبود دهد.

  • TPM اداری

حتی بهترین فرایندها درنهایت کم اثر می‌شوند اگر باتوجه به نیازهای سازمان و تکنولوژی روز، پایش و بروزرسانی نشوند (مایکل همر، پدر علم بازمهندسی فرایندها). فرایندها هسته‌ی اصلی گردش کار و اقداماتی هستند که در سازمان اجرا می‌شود. افزایش بهره‌وری در فعالیت‌های مدیریتی و پشتیبانی  یکی از موثرترین گام‌ها در رسیدن به اهداف TPM است.

  • ایجاد زیرساخت‌های ایمنی، سلامت و محیط زیست

یکی از ارکان نگهداری و تعمیرات بهره ور فراگیر ایجاد زیرساخت‌های امن برای کار در سازمان است. TPM معتقد است که انجام اقدامات مختلف در راستای بهبود و افزایش بهره‌وری سازمان همواره باید درجهت ایمنی و سلامت افراد و جامعه باشد. از این رو این رویکرد می‌تواند سایر ارکان TPM را نیز تحت الشعاع قرار دهد.

آیا اجرای TPM برای سازمان ما موثر است؟

پاسخ به این سوال چندان مشکل نیست. بیایید ابتدا به جایگاه TPM در مدل‌های معتبر مدیریت دارایی‌های فیزیکی نگاهی بیندازیم:

همانطور که در مدل تعالی بالا (مدل آپتایم) هم مشخص است جایگاه TPM، در استراتژی‌های مربوط به سطح تعالی سازمان است و پیش از رسیدن به تعالی، پیش‌نیازهای زیادی وجود دارد. به پشتوانه سال‌ها تجربه در بحث مدیریت دارایی های فیزیکی و فرهنگ سازمانی معتقدیم که اجرای TPM قبل از گذراندن پیش‌نیازها اگر چه ممکن است آورده‌های کوتاه مدت و حداقلی داشته باشد ولی هرگز منجر به رسیدن به اهداف اصلی نگهداری و تعمیرات بهره ور فراگیر TPM نخواهد شد، حتی ممکن است عوارض و آسیب‌های بیشتری را به سازمان شما تحمیل کند. چه بسا یک شوق و انرژی و نیاز به تغییر مثبت در سازمان ایجاد شده باشد ولی به علت نبودن زیرساخت‌های لازم، اجرای پروژه با شکست مواجه شود. همه می‌دانیم که در این نوع سیاست‌های کلان که کل شرکت را در بر می‌گیرد، بازگشت دوباره به مراتب سخت‌تر و هزینه بردارتر است.

شرکت پمکو به پشتوانه ­سال‌ها تجربه در حوزه ­ی مدیریت دارایی های فیزیکی و به کمک کارشناسان متخصص و با تجربه در این حوزه، به شما کمک می‌کند تا سازمانتان را ارزیابی کنید و متناسب با نوع کسب و کارتان بهترین رویکرد تعالی را انتخاب و آن را با موفقیت پیاده سازی کنید.

مطالب مرتبط

دوره آموزشی نگهداری و تعمیرات بهره ور فراگیر
دوره آموزشی نگهداری و تعمیرات بهره ور فراگیر
استراتژی مدیریت دارایی های فیزیکی
استراتژی مدیریت دارایی های فیزیکی
نظام آراستگی محیط کار 5S
نظام آراستگی محیط کار 5S

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