Successfully Deploying Total

Productive Maintenance
Track 4 Session 4
 Eric D. Whitley
Manufacturing Consultant
Productivity, Inc.
ewhitley@productivityinc.com
800.966.5423

Copyright 2007 © Productivity, Inc. All rights reserved

2007 MATERIAL HANDLING & LOGISTICS CONFERENCE SPONSORED BY HK SYSTEMS
Abstract
 This practical tutorial can help you make
impressive gains in maintenance
effectiveness by applying the principles of
Total Productive Maintenance. The goal of
the TPM program is to markedly increase
production while, at the same time,
increasing employee morale and job
satisfaction. Regardless of your current
strategy, the examples and approaches
discussed will further your success
toward system reliability.
Copyright 2007 © Productivity, Inc. All rights reserved
2007 MATERIAL HANDLING & LOGISTICS CONFERENCE SPONSORED BY HK SYSTEMS
Agenda
 Introductionto TPM (Total Productive
Maintenance)
 Review the Five Pillars of TPM
 Understand the Need For Autonomous
Maintenance.
 Takeaways & Questions

Copyright 2007 © Productivity, Inc. All rights reserved

2007 MATERIAL HANDLING & LOGISTICS CONFERENCE SPONSORED BY HK SYSTEMS
 Introduction to TPM

Copyright 2007 © Productivity, Inc. All rights reserved

2007 MATERIAL HANDLING & LOGISTICS CONFERENCE SPONSORED BY HK SYSTEMS
What Is TPM?
 TPM is a plant improvement methodology which
enables continuous and rapid improvement of
the manufacturing process through the use of
employee involvement, employee
empowerment, and closed-loop measurement of
results.
Nakajima, TPM Development Program: Implementing Total Productive Maintenance, Productivity
Press

 Definition:
– A companywide management philosophy, supported by
interlocking developmental strategies, to maximize
equipment effectiveness and eliminate equipment-related
waste
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2007 MATERIAL HANDLING & LOGISTICS CONFERENCE SPONSORED BY HK SYSTEMS
MAINTENANCE –vs-
“FIX/REPAIR”
 Is maintenance value adding or non-value
adding?

 What does maintenance produce that is

MORE valuable to you than the product
itself?

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2007 MATERIAL HANDLING & LOGISTICS CONFERENCE SPONSORED BY HK SYSTEMS
Characteristics of TPM
 Optimum relationships between people
and equipment
 Involvement of everyone, from top
leadership to shop floor workers
A cross-functional approach, involving all
departments
 Implementation through small group
teamwork
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2007 MATERIAL HANDLING & LOGISTICS CONFERENCE SPONSORED BY HK SYSTEMS
World Class Competitiveness
Sustained Profitability
& Customer Delight

Lean Management Systems

Continuous Improvement

Management

Minimum Lead Time Optimal Effectiveness Perfect Quality

JIT TPM TQM

Waste Elimination Maintenance at the Source Quality at the Source
Process Equipment Product/Service

Optimal Creativity and Utilization

Teamwork
100% Participation in Improvement
People Copyright 2007 © Productivity, Inc. All rights reserved
2007 MATERIAL HANDLING & LOGISTICS CONFERENCE SPONSORED BY HK SYSTEMS
TPM Is a Paradigm Shift
Old Attitude
 “I operate, you fix”
 “I fix, you design”
 “I design, you
TPM Attitude
operate”  “We are all
responsible for our
equipment, our
plant, and our
future”

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2007 MATERIAL HANDLING & LOGISTICS CONFERENCE SPONSORED BY HK SYSTEMS
The Old Way vs. the New Way
 Engineers and  Workers are experts;
managers are managers and
experts; workers engineers serve them
serve their dictates
 Cost reduction comes
 Cost reduction comes by speeding the
by driving labor out of product through the
the product and factory without waste
increasing machine
utilization  Do it right the first
time — you don’t
 “Quick and dirty” have time to do it over
often has to be good
enough
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2007 MATERIAL HANDLING & LOGISTICS CONFERENCE SPONSORED BY HK SYSTEMS
Six Major Losses to
Equipment Effectiveness

 Failures  Reduced speed

 Setup/changeover  Defects and rework

and adjustments
 Startup loss
 Idling and minor
stoppages

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2007 MATERIAL HANDLING & LOGISTICS CONFERENCE SPONSORED BY HK SYSTEMS
The Zero-Failure Principle
A failure is the tip of the iceberg!

FAILURES

Wear, play, slackness,

leakage, dust, dirt, corrosion,
deformation, adherence of raw Expose hidden
materials, surface damage, cracking, abnormalities and
overheating, vibration, noise, prevent quality and
and other abnormalities functional failures
before they happen
Hidden abnormalities

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2007 MATERIAL HANDLING & LOGISTICS CONFERENCE SPONSORED BY HK SYSTEMS
The Five TPM Pillars
Early
Equipment
Management/
Maintenance
Prevention
Design
Training and Autonomous
Skill Development Maintenance

TEAMS

Systematic Maintenance
Equipment Process
Improvement Improvement

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2007 MATERIAL HANDLING & LOGISTICS CONFERENCE SPONSORED BY HK SYSTEMS
 Autonomous Maintenance

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2007 MATERIAL HANDLING & LOGISTICS CONFERENCE SPONSORED BY HK SYSTEMS
What is Autonomous
Maintenance?
 The ability of the machine operator to perform
daily tasks to help with maintaining the
production equipment.
 The education of the operator with respect to
the functions and systems of the production
machinery.
 The release of daily tasks from maintenance
department, giving them the ability to focus on
more proactive maintenance measures.

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2007 MATERIAL HANDLING & LOGISTICS CONFERENCE SPONSORED BY HK SYSTEMS
The 7 Steps of
Autonomous Maintenance
 Initialcleaning and inspection
 Eliminate contamination
 Establish provisional standards
 Develop and train inspection standards
 Inspect regularly and improve procedures
 Workplace management
 Participate in advanced improvement
activities

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A View of Equipment Losses
Equipment poorly designed,
maintained, or managed
Deterioration

Slight abnormalities

Unnoticed or ignored

Chronic losses Sporadic losses

Lost availability,
performance, and quality
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Baby Gators Are Virtually Harmless

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2007 MATERIAL HANDLING & LOGISTICS CONFERENCE SPONSORED BY HK SYSTEMS
The gator is/was 18' 2" long.

Copyright 2007 © Productivity, Inc. All rights reserved

2007 MATERIAL HANDLING & LOGISTICS CONFERENCE SPONSORED BY HK SYSTEMS
 Copyright 2007 © Productivity, Inc. All rights reserved
2007 MATERIAL HANDLING & LOGISTICS CONFERENCE SPONSORED BY HK SYSTEMS
 Copyright 2007 © Productivity, Inc. All rights reserved
2007 MATERIAL HANDLING & LOGISTICS CONFERENCE SPONSORED BY HK SYSTEMS
 Copyright 2007 © Productivity, Inc. All rights reserved
2007 MATERIAL HANDLING & LOGISTICS CONFERENCE SPONSORED BY HK SYSTEMS
 Copyright 2007 © Productivity, Inc. All rights reserved
2007 MATERIAL HANDLING & LOGISTICS CONFERENCE SPONSORED BY HK SYSTEMS
 Copyright 2007 © Productivity, Inc. All rights reserved
2007 MATERIAL HANDLING & LOGISTICS CONFERENCE SPONSORED BY HK SYSTEMS
Case Study
 Organization: Major Manufacturer of Industrial
and Communications Wire and Cable.
– Project Duration: >1 year; 3 Facilities.
– Client Project Objectives: Diffuse company-wide
Autonomous Maintenance effort and
– internal Trainer Certification.
 Major Events:
– 4 TPM Leadership Training Workshops.
– Facilitated >16 kaizen events.
– >150 employees Trained in Autonomous Maintenance.
– 4 Certified Autonomous Maintenance Trainers.

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2007 MATERIAL HANDLING & LOGISTICS CONFERENCE SPONSORED BY HK SYSTEMS
Case Study
 Aggregate Audited Outcomes: Facility
specific include: Mean-time between
failures
– (MTBB) improved 48%, OEE from 48% to 55%,
wire breaks @ 5 per shift reduced
– to 3 breaks in 3 months, numerous equipment
redesign projects. On-going project.

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2007 MATERIAL HANDLING & LOGISTICS CONFERENCE SPONSORED BY HK SYSTEMS
Case Study
 Organization: Large Chemical Mining
Operation
– Project Duration: 2.5 years. On-going.
– Client Project Objectives: Stabilize and Reduce
Maintenance Related Cost. Improve
– Production Out-put.
 Major Events:
– TPM Action Planning
– Implement TPM/AM
– Train-the-trainer – 4 trainers certified
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2007 MATERIAL HANDLING & LOGISTICS CONFERENCE SPONSORED BY HK SYSTEMS
Case Study
 Aggregate Audited Outcomes:
Maintenance Cost Stabilized. Production
Output
– Improved by 37%. $1.6M in Product Leaks
Eliminated (Documented Savings).
– “Boil-outs”- Before 1 every 4 days Now 1 every
17 days.

Copyright 2007 © Productivity, Inc. All rights reserved

2007 MATERIAL HANDLING & LOGISTICS CONFERENCE SPONSORED BY HK SYSTEMS
Key Takeaways
 TPM is a plant improvement process that
includes everyone.
 The maintenance process should add
value.
 Poor equipment performance will hinder
material flow.
 Start by implementing Autonomous
Maintenance.

Copyright 2007 © Productivity, Inc. All rights reserved

2007 MATERIAL HANDLING & LOGISTICS CONFERENCE SPONSORED BY HK SYSTEMS
Roadmap

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2007 MATERIAL HANDLING & LOGISTICS CONFERENCE SPONSORED BY HK SYSTEMS
Resources
 www.productivityinc.com

 www.productivitypress.com

 Autonomous Maintenance for Operators

– Author, Japan Institute of Plant Maintenance

 TPM Development Program : Implementing Total

Productive Maintenance
– Author, Seiichi Nakajima

 Introduction to TPM – Total Productive Maintenance

– Author, Seiichi Nakajima
Copyright 2007 © Productivity, Inc. All rights reserved
2007 MATERIAL HANDLING & LOGISTICS CONFERENCE SPONSORED BY HK SYSTEMS
Questions?