Introduction to TPM Objectives and

Benefits
September 29, 2008

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Cross-Functional, Team-Based Improvement Activities

Early Equipment Management

Training & Skill Development

Systematic Equipment Improvement

Maintenance Process Improvement

Autonomous Maintenance

TPM

The Five Pillars of TPM

Textbook Definition
TPM is a plant improvement methodology which
enables continuous and rapid improvement
through use of employee involvement, employee
empowerment, and closed-loop measurement of
results.

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TPM Implementation Nakajimas 12 Steps

1.
2.
3.
4.
5.
6.
7.
8.
9.

Announce Top Managements Decision to Introduce TPM

Launch Educational Campaign
Create Organizations to Promote TPM
Establish Basic TPM Policies and Goals
Formulate a Master Plan for TPM Development
Hold TPM Kickoff
Improve Equipment Effectiveness
Establish an Autonomous Maintenance Program for Operators
Set-up a Scheduled Maintenance Program for the Maintenance
Department
10. Conduct Training to Improve Operation and Maintenance Skills
11. Develop Initial Equipment Management Program
12. Implement TPM Fully and Aim for Higher Goals

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Characteristics of TPM
Optimum relationships between people and
equipment/process
Involvement of everyone, from top leadership to
shopfloor workers
A cross-functional approach, involving all
departments
Implementation through small group teamwork
DATA DRIVEN!!!

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Two Types of Teams

Manager

Manager

Natural team

Natural team

Cross-functional

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Definition(s)
Note: The DREADED M word is not used!!!
So what does maintenance mean anyway
Maintenance = The act of maintaining
Maintain = To keep in a state of order. To keep in
due (rightful, proper, fitting) condition, operation,
or force; keep unimpaired.

Definition(s) cont
Fix and Repair = Maintenance
HOZEN (Maintenance in Japanese) = Maintaining and
preserving perfection through Asset
Management.
TPM = Total Productive Management
TPM = Total Productive Manufacturing

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TPM Goals
Zero accidents
Minimum life cycle
cost

Zero unplanned
downtime
Zero speed losses
Zero defects

Zero waste!
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Results
Overall Equipment Effectiveness (OEE)
Improved
Mean Time Between Failure Improved
Mean Time To Repair Improved
Etc

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Actual GREEN Results

$60K/ Month Facilities Maintenance Savings
$700K Annual Savings Other-than-hazardous-waste
TPM Process applied to facilities maintenance activities

Plant Air System

Plant Lighting during peak Kilowatt usage

Plant Start-up/Shut-down Procedures

Waste Water Treatment System

Note: Above results since 1998

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TPM Is a Paradigm Shift

Old
Old Attitude
Attitude
II operate,
operate, you
you fix
fix
II fix,
fix, you
you design
design
II design,
design, you
you
operate
operate

TPM
TPM Attitude
Attitude
We
Weare
areall
allresponsible
responsible
for
forour
ourequipment,
equipment,
our
ourplant,
plant,and
and
our
ourfuture
future

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Training and Skill

Development

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Why Training and Skill Development

Operators and Maintenance:
Should possess the training and skills
necessary to carry out all of the required TPM
activities so that they have
A clear understanding of the criteria for judging
normal and abnormal conditions
Can be empowered to strictly enforce condition
management rules
The ability to quickly respond to any and all
abnormalities

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Early Equipment
Management (EEM) and
Maintenance Prevention
(MP) Design

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EEM and MP Design

EEM and MP Design are two methods of making
improvements at the earliest possible stage, with the
goal of fix and repair and defect free equipment.
In other words
Operator/Maintenance friendly equipment through
lessons learned on existing equipment and applied
to new equipment during the concept, design, and
installation phase(s).

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EEM/MP Design Involvement

EEM/MP Design is a team approach. The team
should ALWAYS include members from
Maintenance (hourly)
Production (hourly)
Engineering/Technical

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Maintenance Process
Improvement (MPI)
(Planned, Scheduled Maintenance System)

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MPI Tools and Activities

Well trained/skilled craftspeople
Lubrication Management
Preventive Maintenance system
Predictive Technologies
Documentation Management
EEM/MP Design Involvement
Maintenance Management System
Spare Parts Management
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The Maintenance Techniques

Preventive Maintenance preventing
breakdowns
Corrective Maintenance improving or
modifying equipment to prevent breakdowns or
to make maintenance easier
Maintenance Prevention designing and
installing equipment that needs little or no
maintenance
Breakdown Maintenance repairing or fixing
after breakdowns occur

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Systematic Equipment
Improvement
(Improve Equipment Effectiveness)

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SEI
A systematic approach to eliminate waste
through analysis of the 6 major losses utilizing
cross-functional teams to continuously
investigate, test, and implement improvements
with a goal of maximizing equipment
effectiveness.

DATA DRIVEN PROCESS!!!

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Six Major Losses to

Equipment Effectiveness
Failures

Reduced speed

Setup/changeover
and adjustments

Defects and rework

Idling and minor

stoppages

Startup loss

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How the Losses Reduce Effectiveness

Overall
Equipment
Effectiveness

6 Major
Losses

Availability

Perf.
Efficiency

Equipment
Failures

Reduced
Speed

Adjustments
and Set-Ups

Minor Stops
and Idling

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Quality
Rejects and
Defects
Startup
Losses

Autonomous
Maintenance

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What Is
Autonomous Maintenance?
A collaborative team activity involving
production, maintenance, and engineering
An approach that
develops operating and maintenance skills
strengthens communication and cooperation

A series of activities implemented in

well-defined developmental steps

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Seven Steps of
Autonomous Maintenance
1. Conduct initial
cleaning/inspection

5. Conduct general
inspections

2. Eliminate sources of
contamination

6. Improve workplace
management and control

3. Establish provisional
standards

7. Participate in advanced
improvement activities

4. Develop general
inspection training

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Cross-Functional Team Activity

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Zero Breakdown Strategies

Restore equipment
Maintain basic equipment conditions
Adhere to standard operating procedures
Improve operator maintenance skills
Dont stop at emergency fixes
Correct design weaknesses
Study breakdowns relentlessly

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Button-pushers to Process
Owners
Firefighters to Maintainers

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