Unit 2 maintenance strategy _ Class 2 Total Productive Maintenance TPM Slide 1 m aintenance strategies so formal evaluation methods that

assist the process of ma king decisions that serve the function of selecting and scheduling maintenance c oncrete actions. Like any compromise, they have limitations. The assessment of e ach alternative is relative and dependent on organization, interpretation of the potential user and the nature of the respective team. The human factor has a un ique influence on the effectiveness of the strategy is adopted. In the next clas s will present the main features of those known as TPM, RCM and BCM. Slide 2 TPM stands for Total Productive Maintenance ¨ (total productive maintena nce) and is a technique developed in Japan in the 1970s, as a need to improve th e quality of their products and services. Its basic concept ¨ the reformulation and improvement of the corporate structure after the restructuring and improveme nt of people and equipment ¨, with the commitment of all hierarchical levels and organizational change in the position. Slide 3 The TPM is a technique that promotes a workplace where they are always u nited under the same goals: man, machine and enterprise. The TPM is a production management technique that can produce quality products, lower costs and at the right time. It was created with the purpose of providing effective and efficient maintenance, responding to the needs of Manufacturing · just in time ¨ and ¨ to tal quality management ¨. Resorted to an approach based on human factors to solv e problems of maintenance and reliability field. With regard to equipment, means promoting the revolution along the production line, through the incorporation o f the following items: ¨ zero break ¨, ¨ ¨ and ¨ zero defects zero accident ¨. Slide 4 The TPM is the continuity of the development of methodologies maintenanc e techniques, according to three stages precursor, known as: Latin School: This methodology was initiated in France in the mid-1960s. It assumes that the increa se in business productivity is obtained by maintaining, through a computerized, integrated system, mobilizes resources and teamwork of several segments and diff erent levels of hierarchy, motivated and coordinated under a single direction. T he maintenance coordinates working groups at various levels of supervision seeki ng greater efficiency and availability of equipment. Russian Research: In Russia at the end of the decade created the concept 1960fue maintenance cycle ¨ ¨, def ined as the interval between overhauls Two · ¨, involving all adjustments and re placement work performed during this period. Between Two · overhaul ¨, are inter leaved systematic inspections or audits troubleshooting different. This theory w as developed subsequently to the so-called selective maintenance. Tero technolog y: in the early 1970s, England began to use this methodology. The same is the an alysis and implementation of the alternative technique capable of combining the financial, reliability studies, technical and economic assessment and management methods with the aim of making life cycles each time the equipment is less wast eful. Maintenance is the heart of any system tero technology. Slide 5 goals of TPM are: 1. establish a business structure that seeks maximum e fficiency of production or service - overall performance. 2. be on the premises of work, the various mechanisms to prevent loss, giving zero accident, a minimum of defects and failures least, aiming at: to reduce the cost of the life cycle of the production system. 3. involve all departments of the company, starting wi th the production and maintenance, extending to the development, sales, administ ration, etc. In this aspect should be included to third parties. 4. involve ever yone from managers to front-line operators. 5. get zero loss through small group activities simultaneously. 6. improve the quality of personnel: operators, main tainers and engineers. 7. improve the quality of equipment, through maximizing t heir efficiency and life cycle of equipment. 8. improve the results achieved by the company including: sales, customer satisfaction, company image, etc.. Slide 6 For the implementation of TPM should consider the following aspects:

• • • • Human Resources: Through training of maintenance personnel and operations. The P rocess: Through the application of TQC (total quality cycle) Materials: through just in time ¨ ¨ (at the right time to have) the means of production through the techniques of TPM. You can consider that the TPM to work on these aspects of the company promote: P ersonal Improvement: through changing the mindset of all, the spontaneous adopti on of maintenance operators, maintenance personnel training and encouragement to the review machine project, aiming to maintain its life and maintainability. Im provements in machines and installations: through the Gomal efficiency improveme nt, technical efficiency and utilization factor. Improved corporate culture: thr ough the elimination of waiting times, economic performance and creating a safe, enjoyable and pollution. As we can see the TPM is a method that is part of a co mprehensive philosophy that encompasses the entire enterprise and not just produ ction and maintenance. Slide 7 With the development of TPM was found in a fundamental way, in addition to the need of each of the components of the company is looking for cleanliness and organization, to improve their activities and the work environment in a gene ral way, the attributes of order, cleanliness and discipline, also influenced th e productivity improvement, complementing, in this way, the industry group known as the 5s ¨ ¨, which consist of the following: Organization: (use selection.) S eparating the necessities of those unnecessary, providing a destination for thos e who are no longer useful for that environment. Order: (systematization, arrang ement). Save the things necessary in accordance with the ease of use, considerin g the frequency of use, type and weight of the object, according to a logical se quence and practiced, or easy assimilation. When ordering things over the enviro nment is tidy and pleasant to work, and consequently more productive. Clean: (in spection, tape). Remove dirt, checking to find and attack the sources of problem s. It is important that cleaning be done by users of the environment, the machin e or equipment. Toilet: (standardization, health, development). Store hygiene, t aking care to ensure that the stages of organization, order and cleanliness, and achieved, not backward. Discipline: (self-control, education). Complying with t he rules and all that is set by the group. Discipline is a sign of respect for o thers. Slide 8 The TPM is based on eight pillars that sustain it. They refer to the fol lowing: Preventative Maintenance: In this pillar seeks to establish the types of maintenance, ie standardizing maintenance activities by establishing a common l anguage of communication even everyone in the company. Individual improvements i n equipment: The goal is to establish optimal operating conditions of the equipm ent. Preventive Maintenance Project and Life Cycle Cost: This is to establish th e evaluation of the desirability of acquiring more expensive machines, but bette r reliability, maintainability, operability and economics. In the preventive mai ntenance project is an analysis of the history of the computer to determine impr ovements, which aim at eliminating future problems, and consequently reduce the life cycle cost. Education and training: it seeks to plan the training of operat ors, maintainers and engineers from industry, namely the operation and maintenan ce personnel. Maintenance of quality: in this pillar seeks to establish the eval uation of the interference and the operating condition of equipment in the quali ty of the product or service offered by the company with the definition of param eters that can be indicators of this interference. Administrative control: in th is pillar are implemented ¨ ¨ 5s administrative areas, just in time the ¨ ¨ to s hopping areas and materials, the ¨ ¨ kanban for raw materials, parts, tools and equipment for use in offices, the visual man agement box ¨ ¨ deposits and optimization techniques meetings. Environment, Safe ty and Hygiene: refers to the treatment of accident prevention policies, establi

shing the safety recommendations and the adequacy of the system to be implemente d in the Work Order.€Autonomous maintenance: includes the development of awarene ss of the concept that my machine ¨ ¨ and the care I change the inadequate chara cteristics of the workplace. Slide 9 The tool used in TPM is preventative maintenance / predictive ¨ PM ¨, th is discipline is divided into three: 1. The MP analysis of general improvements (outlet - quality - safety). The TPM-EM: the focus is on the direction of the equipment to improve o The aim of the improvement is reduced to zero if possible stops unplanned, defects or loss of quality, and maintain equipment at full capacity. o The RCM is adopted at this stage to compare the availability, maintainability and reliability of its own equipment with the same statistical parameters obtain ed from international databases. 2. The PM itself, that is the classical implantation technique TPM-PM: focused on preventive maintenance / predictive. o In this discipline the RCM is used to establish on a rationale periods of inspection teams. 3. The PM self-TPM-AM: the focus is on au tonomous maintenance. or A degree of autonomy in the maintenance of small grupoestructura is important an d critical to the success of system development. Slide 10 A methodological approach aims to improve overall effectiveness rates o f the teams, encouraging joint work areas inherent in the quality, safety, opera tions, maintenance and other disciplines, taking advantage of the greater author ity of team members to remove barriers, simplify processes and make substantial productivity gains. Slide 11 While critical evaluation tools used, preventive maintenance and condit ion monitoring, the differences among other strategies are: The TPM is a product ion-centered system, its objectives aimed at achieving product m3jora as a resul t of increased rate OEE (rate of effectiveness of equipment), seeking a process free of faults and the increased availability and production. The TPM is based o n the type of teamwork, ensuring a direct influence of the departments involved in operating performance to facilitate removing the barriers that isolate the ma intenance function. Finally, the TPM is not restricted to treatment of the maintenance function. The OEE index (effectiveness of the equipment) includes various sources of performa nce degradation as ooooooo Low productivity High levels of equipment failure, do wntime, high rates of reprocessing, poor product quality, poor safety and high c ost of configuration and commissioning underway. Slide 12 Based on the concept of organizational quality, the TPM fosters creativ e methods of continuous improvement, using the following sequential framework of work: Introduction of TPM message, stressing the type of interdisciplinary team s working o Implement the measurement and recording of the effectiveness index e quipment. or use continuous improvement techniques, demonstrating the progress a nd explore new opportunities. or o Establish processes involving operators and first line maintenance.

Inclusion of updated techniques and preventive maintenance continuous improvement process o To increase the quality of prevention of failures encompassing condition monitoring techniques, predictive maintenance and applications of RCM. Slide 13 The increase in operating efficiency and minimizing errors are provided by a work environment that is characterized by the cleanliness, order and appro priate distribution at the premises concerned and the formal organization of act ivities, respect and self-discipline. To achieve the right environment requires an ongoing program of work that includes the following fields of activity: Self-maintenance: Regular cleaning of equipment. Sorting machinery spaces in ser vice or passive. o Development and implementation of formal lubrication schemes. Routine inspections or maintenance or preventive attitudes to emerging problems or complete and accurate record of equipment failures oo Improvement: or detection and treatment of anomalies. o Definition and implementation of opti mum conditions. o o Maintenance of the optimum conditions. Sustained increase in performance obj ectives. or Applications of continuous improvement to increase the availability Total Quality Maintenance Implementation of continuous improvement and to reduce and eliminate defects and equipment failure. Monitoring and improving the quality of maintenance work carr ied out or removal of deteriorating machinery.€or job development through equipm ent maintenance TPM. or TPM APPLICATIONS: • Human Resources • Processes • Materi als • Implementing TPM Media OBJECTIVES OF MAINTENANCE • Establish a business st ructure • Build the workplace itself as a mechanism to prevent the various losse s • The TPM is the continuity of the development of methodologies maintenance te chnology known as: Latin School Applying Terotecnologias Constellations and uses the industry can be interpreted as: (maintenance of means of production by all companies) SIX Seiton SEIRI SEIKETSO SHITSUKE ORGANISING CLEAN CLEANING ORDER DISCIPLINE THE PILLARS OF TPM 8 1. 2. 3. 4. 5. Productive Maintenance Improvement Project t eam individual in MP / LSC (preventive maintenance / life cycle costs) Education and Training Quality Maintenance 6. Administrative control in July. Environment Safety and Health 8. Autonomous Maintenance tools used in TPM is the maintenanc e Preventive / Predictive and "PM" PM: TPM-EM PM: TPM-PM PM: TPM-AM Increa sed productivity by continuous DIFFERENCES WITH OTHER STRATEGIES • • • It is a system focused on the production rests on the mobility of teamwork is no t restricted to maintaining the function of maintaining Based on the concepts of organizational quality building methods TPM fosters con tinuous improvement, going to work a sequential framework FIELDS OF ACTIVITY • • • Self Improvement Maintenance Equipment Maintenance Total Quality Prevention, reduction of future maintenance •

KEY LOSSES • • Action Mode Outlook CYCLE PERFORMANCE • Condition Assessment • Measurement • Improved TPM IMPLEMENTA TION STAGES • Initial stage • Stage Implementation • Consolidation Phase Deliver ables to implement the TPM According to reports released by the JIPM (Japan INST ITUTE of plant) Mantennancy to the implementation of TPM can obtain tangible and intangible effects