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TPM-Quality Maintenance

Quality Maintenance aims to establish and maintain "zero-defect conditions" to prevent defects from occurring. This involves setting production processes up to not produce defects, and ensuring processes always operate under those conditions. It requires controlling the causes of quality by monitoring conditions like machinery, materials, methods and personnel that affect quality, and taking preventive action before conditions exceed standards. The goal is to maintain perfect equipment and processes to consistently produce 100% good products by keeping conditions like precision and material properties within predetermined ranges.

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267 views6 pages

TPM-Quality Maintenance

Quality Maintenance aims to establish and maintain "zero-defect conditions" to prevent defects from occurring. This involves setting production processes up to not produce defects, and ensuring processes always operate under those conditions. It requires controlling the causes of quality by monitoring conditions like machinery, materials, methods and personnel that affect quality, and taking preventive action before conditions exceed standards. The goal is to maintain perfect equipment and processes to consistently produce 100% good products by keeping conditions like precision and material properties within predetermined ranges.

Uploaded by

amie indra
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Source : https://leanmanufacturing.

online/what-is-quality-maintenance/

What is Quality Maintenance?


The only way we can achieve our goal of zero quality defects is to discard the reactive,
“shutting the stable door after the horse has bolted” type of approach, where we only
examine quality after it has already been built into the product.
Instead, we must set our production processes up in such a way that they cannot
produce any quality defects and then ensure that the processes always operate under
those conditions.
In Quality Maintenance, this is called “establishing and maintaining zero-defect
conditions”. In other words, to build quality into the product by means of the process, as
quality experts have been urging us to do for decades, we must switch from controlling
the outputs of our processes (the quality of our products) to controlling the causes of
quality (the process and equipment conditions themselves).
If we really want to create a system that ensures perfect quality, we must prevent
defects from happening at all, rather than just screening them out after they have
happened. To do this, we must build a system for controlling the causes of quality – in
other words, we must establish and maintain the “zero-defect conditions” mentioned
earlier. “Controlling quality through its causes” is the essence of Quality Maintenance.
Quality Maintenance is based on the idea of maintaining perfect equipment in order to
maintain perfect quality (i.e. 100% good products). Essentially, it involves:

 Establishing zero-defect conditions in order to create equipment that does not produce any
quality defects, and checking and measuring those conditions periodically,
 Preventing quality defects by keeping those conditions within a standard range of values,
 Predicting the possibility of quality defects by monitoring trends in the measured values, and
taking preventive action.
The Definition of Quality Maintenance

An Illustration of the Definition of Quality Maintenance

To consistently produce 100% good product, we must specify clearly which conditions
relating to the 4 Ms (machinery, materials, men/women, methods) have to be controlled,
together with the range of values they must be restricted to.

Check and Measure Conditions Periodically


If we want to identify potential causes of equipment under-performance, and rectify
them before an unwanted result actually occurs, then we must check the specified
conditions routinely (either daily or at longer intervals) to confirm that they remain within
their permitted ranges.
Prevent Quality Defects by Keeping Conditions within
Standard Ranges
To avoid defects, we need to take preventive action, such as restoring basic operating
conditions to prevent accelerated decline of equipment functions.

Monitor Trends and Predict Possible Occurrence of Quality


Defects
A “zero-defect condition” is defined as a condition that will not cause quality defects if
kept within its standard range. We therefore need to understand the mechanisms of
equipment deterioration, and estimate the rate at which our equipment deteriorates, so
that we can predict when a condition is likely to exceed its standard range.

Take Preventive Action


Losses arising from equipment malfunction must be prevented before they occur. This
requires us to halt the equipment and take corrective action whenever the occurrence of
a defect has been predicted, or restore functions systematically during periodic
servicing.

The Basic Philosophy of Quality


Maintenance
To prevent quality defects due to equipment or process conditions, we have to establish
the conditions under which the equipment or process will not produce any defects. To
do this, we must fully co-ordinate our quality assurance activities and equipment
management activities, and identify how the product’s quality characteristics are
affected by materials, methods and equipment precision.

Establishing zero-defect conditions involves identifying the exact group of causes


behind any possible defects, and then setting ranges for the material conditions, method
conditions and equipment precision, so as to ensure 100% good product. The central
philosophy of Quality Maintenance is to sustain and control the established conditions,
and consequently achieve zero defects, and this approach relies on having operators
who are fully conversant with their equipment and have been trained in Autonomous
Maintenance and other relevant skills (see Figure “The Basic Approach to Quality
Maintenance”).
Achieving perfect quality requires an important shift in attitude – from the conventional
approach, where defects are only discovered when the product is inspected, and action
is taken after the event, to an approach in which each condition affecting quality is
measured periodically, and preventive action is taken before that condition exceeds its
permitted range.
This chapter looks at how to establish, standardize and improve zero-defect conditions
for materials, machinery and methods.

The Basic Approach to Quality Maintenance

The 4 Ms – the Determinants of Quality


The key to ensuring quality (i.e. production standards) on the shop floor is achieving
optimal conditions for the 4 Ms (Men/Women, Machinery, Materials, Methods), see
Table “The 4-M Conditions – The Determinants of Quality”.
Improving quality means establishing optimal conditions for the 4 Ms, raising the quality
assurance capability (Cp) of the process until it stabilises at a high level, and setting
work standards and inspection standards to maintain that capability. Sustaining quality,
on the other hand, means faithfully applying the work standards and inspection
standards that maintain the optimum conditions we have set. Figure “The 4-M
Conditions – The Determinants of Quality” illustrates this relationship.

The 4-M Conditions – The Determinants of Quality


The 4-M Conditions – The Determinants of Quality

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