TPM | Africa | Tendele Consulting

Manufacturing Excellence

Turning conventional thinking

on its head

In 1972, the Japanese Institute of Plant Maintenance began promoting Total Productive Maintenance (TPM) as a means to increase quality and productivity.

Total Productive Maintenance translates into productive maintenance activities in which all employees from top management to operators participate in company-wide identification and total elimination of all forms of loss and waste, resulting in:

• zero breakdowns • zero defects • zero accidents •

Tendele Consulting, formerly trading as TPM Africa, brings 25 years practical experience in this field. Once you turn conventional thinking on its head, as TPM does, you’ll see amazing results.

TPM Awareness

The TPM Awareness workshop provides an overview of TPM theory and application.

As part of the overview, the main principles and key factors for successful implementation are discussed, including the possible need to change the corporate culture, as well as getting every department and employee involved, from top management to front line operators.

Indicators are also provided around alignment of TPM practices into the organisational business plan.

TPM Audits

An initial audit is carried out based on nine pillars of TPM. A report is compiled including results from interviews, the audit assessment and visuals to support findings. During a half day session, feedback is provided to the senior management team and selected stakeholders. This is the starting point for developing transparency in the organisation. It also communicates the serious intentions of the management team in working towards the achievement of World Class standards

5S System

of Workplace Organisation

In a world of short lead times, shrinking product life cycles, ever-changing customer requirements and uncertain demand, manufacturing companies need to be innovative in product development and supremely flexible in manufacturing.

The 5S system of Workplace Organisation is a highly successful Japanese industrial housekeeping system to promote clean, organised and disciplined working environments, which by themselves are more efficient and stimulating for employees. They also provide the ideal foundation for more advanced world class manufacturing concepts such as Total Quality and Lean Manufacturing.

TPM Awareness

TPM Audits

5S Systems

Quick Changeovers / SMED

This three-day theory and application workshop is based on the work of Shigeo Shingo, a Japanese Industrial Engineering Consultant who developed the original concepts of changeover reduction.

The application of his techniques has proved highly successful in a broad range of situations, with many companies being able to cut the time taken on product changeovers from hours to just a few minutes.

Today, for any company faced with volatile demands from their customers, such changeover speed is essential to improve process flexibility and to allow reductions in stock levels and manufacturing lead times.

Autonomous Maintenance

Autonomous Maintenance (AM) is a concept unique to TPM and involves operators of machines being encouraged and trained to undertake daily basic machine care. This practice releases skilled personnel to concentrate on equipment improvement and preventative maintenance, as well as establishing an organised shop floor where any problems are immediately obvious.

Operating teams taking part in an autonomous maintenance project will be led through the seven steps of the AM maintenance programme – beginning with the establishment of proper routines for the cleaning, lubrication and tightening of equipment, through to involving operators in process improvement activities to achieve the goals of ‘zero breakdowns’, ‘zero accidents’, and ‘zero defects.’

Workplace Teams

Teams are the basic unit of performance for most organisations, regardless of size. In any situation requiring the combination of multiple skills, experiences and judgments, a team inevitably gets better results than a collection of individuals operating within confined job roles and responsibilities.

Teams are more flexible than larger organisational groupings because they can be more quickly assembled, deployed, refocused, and disbanded, usually in ways that enhance rather than disrupt more permanent structures and processes.

Campaign Management

Campaign management is the art and science of creating the visual, auditory and kinesthetic experiences that support awareness and acceptance of transformation initiatives.

Particular focus is given to workplace structures where visual management tools and techniques provide real time measures for performance, quality and morale and create a shared perception of reality.

A significant component of the TPM 5S system is the implementation of visual management that defines a team's

territory, green areas, visual documentation, visual production control, visual quality control and process indicators.

Our campaign management processes are effectively rolled out in conjunction with TPM projects, IT upgrades and employee wellness programmes although it can be implemented as a stand-alone project.

Autonomous Maint.

Changeovers / SMED

Workplace teams

Campaign Mngmnt