Abstract
This chapter discusses total productive and reliability-centered maintenance (RCM) at Beta International. The first step in combining total productive maintenance (TPM ) and RCM principles is to perform a streamlined failure modes and effects analysis (FMEA)/ RCM analysis of a given production line, that is, at a business system level. The FMEA/RCM portion of the analysis defines a functional failure as anything that causes loss of production capacity or results in extraordinary costs. It is focused on failure modes, frequencies, and effects and is extended to identify those failure modes that would be readily detected and prevented by proper operator action. It also details those failure modes and effects that require more advanced methodology and techniques, such as predictive maintenance, better specifications, better repair and overhaul practices, and better installation procedures to avoid the defects from being introduced in the first place. The next step is to apply TPM principles related to restoring equipment to like-new condition, having operators provide basic care in tightening, lubricating and cleaning, and applying more effectively preventive and predictive techniques. The company found that combining TPM and RCM actually led to a better process, improvements in teamwork, and cooperation at the production level; leading to improved performance, and output, and lower operating costs.
Published Version
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