IMPEM131 – Apply total productive maintenance (TPM) in food and drink operations
Overview
This standard covers the competences required to apply Total Productive Maintenance (TPM) principles to equipment and processes used in food and drink operations, and aims to prevent equipment problems by identifying potential causes rather than waiting for a problem to occur. It involves the measurement of the six classic hidden losses, assessment of potential and priorities for loss reduction. It covers the application of the TPM principles and processes to resources, including plant and equipment, machines, office equipment, service equipment and utilities. It also concerns assessment of the equipment/process condition, the steps required to restore the equipment/process to good working order, and then to set a robust asset care regime to maintain this condition. Food and drink operations is a term used in this standard to cover the following sub sectors of Meat, Drinks, Confectionery, Fresh Produce, Bakery, Seafood and Dairy.
You will be able to apply the appropriate TPM techniques, and to use the data gathered on the resource to refine the working practices through the application of autonomous, condition based and planned maintenance. Working practice improvement will include cleaning and checking, early problem detection and process monitoring, and routine servicing. This will involve close working with both production and maintenance staff, and will include cross-shift implementation (if applicable to your organisation).
You will be able to take full responsibility for your own actions within the activity, and for the quality and accuracy of the work that you carry out.
Applying safe working practices will be a key issue throughout, especially related to food safety risks.
Performance criteria
You must be able to:
work safely at all times, complying with health and safety and other relevant food and drink regulations, directives and guidelines
select the appropriate asset on which to carry out the Total Productive Maintenance (TPM) activity
obtain the necessary information to carry out the activity
carry out the TPM activity by applying the appropriate techniques in accordance with organisational procedures
calculate and use the overall equipment effectiveness (OEE) measure and information to determine which elements of the OEE and their associated losses need improvement
develop and use an action plan which will reduce/eliminate the losses in accordance with organisational procedures
implement improvements to working practices through the TPM activities in accordance with organisational procedures
Knowledge and understanding
You need to know and understand
the food and drink related health and safety requirements of the area in which you are carrying out the Total Productive Maintenance (TPM) activities
the principles of TPM, and how they can be applied in administration procedures, safety improvement and quality maintenance within food and drink operations
the requirements of the British Retail Consortium (BRC) guidelines and standards in relationship to the maintenance activities
the specific requirements of your customer/client specifications in relationship to the maintenance activities
your responsibilities in relationship to Hazard Analysis and Critical Control Points (HACCP, TACCP, VACCP) during the maintenance activities
how to select an asset on which to carry out the TPM activity as an initial pilot area (assets can be plant and equipment, machines, office equipment, service equipment, utilities)
how to implement a systematic and structured approach to carrying out autonomous, condition based and planned maintenance
the difference between a chronic and sporadic loss, and the countermeasures to both
how to calculate overall equipment effectiveness (OEE)
where to find the information required to calculate the OEE for the chosen asset
the benefits of having a TPM system
the importance of taking ownership of the TPM system, and the issues that can be expected to be resolved
the six major losses (including Breakdowns, Set-up and adjustments, Small stops, Slow running, Start-up defects and Production defects) their impact on OEE and how loss-reduction actions need to be prioritised
the use of standard operating procedures, single point lessons and machine/process start-up and shutdown procedures
improvement activities that will drive the implementation of the TPM activities (including Kaizen and team working)
critical processes and early problem detection steps
loss areas and opportunities for improvement
standards of wear, and the ability to stabilise the component life
the techniques of visual management used to communicate the information and results obtained by this process (including TPM activity boards and checklists)
the integration with workplace organisation and improving OEE
possible contaminants and their sources
the extent of your own authority, and the relevant escalation procedures in the event of problems that you cannot resolve
Keywords: Food and Drink; Engineering; business; improvement; techniques; total productive maintenance; TPM; production losses; equipment conditioning; care regime
IMPEM131 – Apply total productive maintenance (TPM) in food and drink operations
Overview
This standard covers the competences required to apply Total Productive Maintenance (TPM) principles to equipment and processes used in food and drink operations, and aims to prevent equipment problems by identifying potential causes rather than waiting for a problem to occur. It involves the measurement of the six classic hidden losses, assessment of potential and priorities for loss reduction. It covers the application of the TPM principles and processes to resources, including plant and equipment, machines, office equipment, service equipment and utilities. It also concerns assessment of the equipment/process condition, the steps required to restore the equipment/process to good working order, and then to set a robust asset care regime to maintain this condition. Food and drink operations is a term used in this standard to cover the following sub sectors of Meat, Drinks, Confectionery, Fresh Produce, Bakery, Seafood and Dairy.
You will be able to apply the appropriate TPM techniques, and to use the data gathered on the resource to refine the working practices through the application of autonomous, condition based and planned maintenance. Working practice improvement will include cleaning and checking, early problem detection and process monitoring, and routine servicing. This will involve close working with both production and maintenance staff, and will include cross-shift implementation (if applicable to your organisation).
You will be able to take full responsibility for your own actions within the activity, and for the quality and accuracy of the work that you carry out.
Applying safe working practices will be a key issue throughout, especially related to food safety risks.
Performance criteria
You must be able to:
Knowledge and understanding
You need to know and understand
Keywords: Food and Drink; Engineering; business; improvement; techniques; total productive maintenance; TPM; production losses; equipment conditioning; care regime