Introduction: TPM

Presented by Andy Ginder

Vice President, ABB Reliability
Consulting
281-450-1081
Andy.p.ginder@us.abb.com
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Objectives
Learn the main elements and features of TPM
Know the stages and steps of a TPM program and their
purpose, and appreciate the benefits of the process
Understand how preventive maintenance, 5S, SMED and
other activities apply to TPM
Understand how the feedback process works, and how
equipment effectiveness is measured
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Total Productive Maintenance

A plant improvement methodology
Enables continuous and rapid improvement of the
manufacturing process
Extensive use of employee involvement, employee
empowerment
Small groups

Closed-loop measurement of results.

Key performance measures or indicators provide feedback
to the process to support continuous improvement
OEE
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Equipment Reliability
The probability that equipment or systems will
perform required functions satisfactorily under
specific conditions within a certain period of time.
Intrinsic: based on design
Determined during the design, fabrication, and
installation stages.

Operational: determined by the user

Related to how and under what conditions the
equipment is operated and maintained.
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Evolution of TPM

Feedback and Measurement

Feedback and Measurement

Check Examine and Expose
problems
Act Counter & Solve problems
Plan Prevent recurrence through
improvement
Do Execute & follow standards &
rules
Autonomous Maintenance Approach

C
A
P
D

Optimal Conditions

A
P
D
C

A
P

Check
Act

Plan
Do
C

Feedback and Measurement

Feedback and Measurement

Core Elements of TPM

Paradigm shift from the typical perceptions of who is
responsible for maintenance.
Maximize overall equipment effectiveness.
Establish a thorough maintenance system for the entire life
span of the equipment.
Implement by all departments including engineering,
operations, maintenance, environmental, purchasing,
accounting, stores, safety, and human resources.
Involve every employee, from top management to hourly
employees.
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TPM Program Stages (4)

Stages
I. Preparation
II. Preliminary Implementation
III. TPM Implementation
IV. Stabilization
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TPM Program - 12 Steps

Stage I. Preparation
1. Formulate master plan for TPM implementation
2. Announce top managements decision to
introduce TPM
3. Launch education program and campaign to
introduce TPM
4. Create organizations (teams) to promote TPM
5. Establish basic TPM policies and goals
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The TPM Goals/Process

Define the Vision - Should be a Stretch Goal
Create the Mission Statement
Minimal: Concise, short and sweet
Memorable: A rallying cry
Measurable: You know when you have arrived,
a concrete step toward attainment of your vision

Define Core Values

Develop Strategies
Create Key Performance Indicators
Define Critical Activities

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TPM Program - 12 Steps

Stage II. Preliminary Implementation
6. Hold TPM kick-off
Stage III. TPM Implementation
7. Improve effectiveness of each piece of
equipment
8. Develop an operator performed maintenance
program
9. Develop a scheduled maintenance program for
the Operations and Maintenance departments
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Sample Operator Tasks

Housekeeping and
cleaning equipment
Visual checks and
inspections
Changing filters
Dismantling obsolete
piping and tubing
Removing insulation

Tightening loose
connections, hardware,
belts
Repairing steam leaks
Adjusting valve packings
Greasing valves
Installing line clamps
Doing minor painting
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Criteria for Selecting Operator

Tasks

Safety
Time requirements
Task receptivity
Task timing
Task complexity

Task frequency
Task criticality
Training requirements
Tool and material
requirements

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Support Tools

Basic hand tools

Detailed inspection sheets or checklists
Equipment logs
Specific written procedures
Visual graphics, routes, diagrams
Color coding (marked lube points), equipment
numbers

Equipment markings or stamped plates

Operator backlogs and performance indicators
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TPM Program - 12 Steps

Stage III. TPM Implementation (cont)
10. Conduct training to improve operation and
maintenance skills
11. Develop equipment management or
maintenance prevention program
Stage IV. Stabilization
12. Perfect TPM implementation and raise TPM
levels
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Sustaining the Process

Self-Sustaining is a Myth. Requirements are:
Active Champions and Sponsors
Knowledgeable and Motivated People
A Holistic Strategic Approach Supported by Tactical
Plans
Emphasis on Practical (Real-World) Application of
Theoretical Concepts
Ongoing Internal Reinforcement
Integrated with Appropriate Rewards and Incentives
Supplemented by Periodic External Interventions
Backed by Audit Process

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What is 5S?
A process designed to organize the
workplace, keep it neat and clean, maintain
standardized conditions, and instill the
discipline required to enable each
individual to achieve and maintain a world
class work environment.

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What are the 5Ss?

1. SEIRI - Sort
2. SEITON - Set in order
3. SEISO- Shine
4. SEIKETSU - Standardize
5. SHITSUKE- Sustain
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Before

After
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Evolution Intangible Benefits

Clean Environment

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Evolution Intangible Benefits

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Evolution Intangible Benefits

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Evolution Intangible Benefits

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SMED

SMED: Single-Minute Exchange of

Die

Internal Setup: Operations that are

performed while a machine is stopped
External Setup: Operations that are
performed while a machine is running

SMED was originally designed to improve die press

setups but its principles apply to changeovers in all
types of processes
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3 Phases of SMED
Separating Internal
and External Setup
Converting Internal
Setup to External
Setup
Streamlining all
Aspect of the Setup
Operation

SMED

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Preventive Maintenance
PM Analysis Procedure
Clarify the problem
Conduct a physical analysis of the problem
List every condition potentially related to the
problem
Evaluate equipment, materials, and methods
Plan the investigation
Investigate malfunctions
Formulate improvement plan
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Preventive Maintenance and

Maintenance Standards
Maintenance Standards
A. Equipment maintenance standards
1. Inspection standards for measuring equipment
deterioration
2. Overhaul standards for preventing equipment
deterioration
3. Repair standards for restoring equipment
B. Maintenance work procedures
1. Procedures showing work practices and times
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Questions

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