Decintell Falco: Decintell Falco Total Preventive Maintenance (TPM) Module

Decintell Falco Total Preventive Maintenance (TPM) Module

Decintell Falco Knowledge Platform is a complete enterprise suite consisting an array of modules to cover enterprise wide transactions and workflows. The platform comes with its own Admin Centre. Admin can create roles, create users, assign roles and access rights. Configure alerts, emails etc. Admin can also monitor users' login sessions in real time and can force logout or suspend a user. Admin Centre is a very powerful tool to grant user level access to ensure information integrity. Apart from Admin Centre, Falco combines a set of standard modules and customised modules to handle complicated workflows within an Enterprise. (for more about Admin Centre click Decintell Falco Admin Centre

The standard modules are My KRA BI Dashboards, DOIT (IoT module to monitor equipment performance), WAC (weighment calibration app). The customized workflows are SWAS (an aftermarket suite), CPC (Constraint based Capacity Planning and Control), ECM (Engineering Change Management), CEM (Customer Engagement Management), TPM (Total Preventive Maintenance), NPD (New Product Development) and many more. (for more on Decintell Falco Knowledge Platform click Digitise with Decintell Falco Knowledge Platform).

For the scope of this blog we will discuss TPM module in detail. TPM stands for Total Preventive Maintenance. Frequently TPM is also as defined as "Total Productive Maintenance" or "Total Predictive Maintenance".

Even at the cost of a little digression, I would like to discuss various definitions. Properly maintained machines and equipment does have high productivity, higher uptimes, higher quality reliability and of course longer machine working life. And collectively calling all these as "Productive" may be the intent behind using the term "Total Productive Maintenance".

Let us look at another definition of TPM. Total Predictive Maintenance. Can we really have "predictive" maintenance. For anything to be "predictive" one assumes that all potential failures of a machine, can be predicted. Yes, in theory it can be. But practically it is extremely difficult to achieve that, if not impossible. All the predictions are possible only thru past data. For any predictive pattern to be established, large amount historical data is needed and that too, accurately recorded. If an organisation starts building record for every machine thru regular preventive maintenance, breakdowns, spares changes, over years, then that can certainly be used by an artificial intelligence algorithm to come up with certain predictions. But therefore, calling it Predictive is going a bit overboard. I would suggest, not to get influenced with terms like Artificial Intelligence or Block Chain etc. As technologies, they may be advanced and effective, but the question is more about their actual utility in absence of consistent and large amount of data.

I am, therefore, personally more aligned with "Total Preventive Maintenance" as a definition of TPM. Total Prevention is a feasible target for an organisation. The intent of TPM is to ensure equipment health, so the breakdowns are minimized. And as a consequence, capacity calculations get more reliable. TPM has to be part of culture and has to be sustained constantly. TPM is not a one-time project, an activity for the month, or some yearly program. It is a culture. Many a times TPM initiatives fade out over a period because of lack of consistent monitoring.

Decintell Falco Knowledge Platform hosts a powerful TPM module.

TPM module enables the maintenance team

Draw maintenance schedule for every equipment for the entire year
Assign teams for the schedule
Keep team attendance and holiday calendar especially because they will have staggered weekly off schedule and will be entirely different from the rest of the personnel.
Centrally prepare checklists for every equipment along with part replacement plan
Plan spare parts
End to end breakdown ticket handling
Realtime feedback loop with Falco Capacity and Production Control (CPC)
Analytics