TPM

Total Productive Maintenance / Strategy for 11 / 16

Effective and Productive Maintenance

World-Class Standards & Best Practices of Operational Excellence

© Lean & Mean Consulting. All rights reserved. 2016
2015
 LEAN Management Academy - Outline
Knowledge & Expertise / Editable Training Presentations / 16 Modules

World-Class Standards & Best Practices of Operational Excellence

© Lean & Mean Consulting. All rights reserved. 2016
Training Objectives

 Understand the concept and philosophy of TPM

 Learn the 8 pillars of TPM activities and step-by-step

implementation approach

 Learn the TPM tools and be able to identify and eliminate loss

 Learn how to kick-start TPM deployment with Autonomous

Maintenance, Planned Maintenance, Focused Improvement,
and Education & Training activities to improve equipment
effectiveness

 Understand the roles of a TPM implementation organization and

the critical success factors

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Agenda

 Introduction to TPM Philosophy

 TPM Fundamentals
 TPM Key Components
 Equipment Loss & OEE
 8 Pillars of TPM Strategy
 Autonomous Maintenance
 Approach to TPM Implementation
 Critical Success Factors

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Module. 11

Total Productive Maintenance

1
 Machine failures have many hidden causes

Failure is what we see Visible

but is only the tip of the

Failure
iceberg

Wear
Improper Temperature
Flaws
Leaks
Corrosion
Contamination

Cracks Backlash
Loosening
Minor machine defects are Deformation
generally unnoticed but are Less
the cause of almost all Vibration
machine failures Visible

6
What is TPM?

Total Productive Maintenance (TPM) is a method to

achieve maximum equipment effectiveness through
employee involvement

Management + Operators + Maintenance

7
TPM is a paradigm shift 1

Operator Maintenance

I use You maintain &

We maintain !
I fix
Old Attitude TPM Attitude

8
TPM is a paradigm shift 2
Old Philosophy
 I operate, you fix, he designs. . .
 Quality is costly. . .
 Supervisors & engineers are
experts. . .
 Defects, speed losses & unplanned
downtime are inevitable…
 Inventory is useful
New philosophy
 We are all responsible for our
equipment.
 Quality is free.
 Operators/Maintenance are
experts too.
 Zero defects, zero speed losses,
zero unplanned downtime.
 Inventory is costly.
TPM eliminates/reduces waste
Over
production
Producing more
Intellect than what the Waiting
Not using customer needs
employees full Employees waiting
intellectual for another process
contribution or information

Over Motion
processing
Extra physical /
Adding excess value mental motion that
when the customer doesn’t add value

Waste
does not require it

Defects Transportation
Reprocessing, or Moving from one
correcting work Inventory place to another
Building and storing
products the
customer has not
ordered

10
TPM – Why do it?
 Reduce manufacturing costs (COO-Cost of Ownership)

 Maximize the effective use of plant equipment (increase

OEE-Overall Equipment Effectiveness)

 Optimize skills of the operations and maintenance

personnel

 Improve on-time deliveries

 Shorten Lead Times

 Improve Customer Satisfaction

11
TPM Goals

 Maximize equipment
effectiveness
 Zero breakdowns
 Zero defects
 Zero accidents

Zero waste!

12
 TPM goals (continued)

TPM aims at getting the most efficient use of equipment and establishes a
planned maintenance system including:

 maintenance prevention
 preventive maintenance
 and improvement-related maintenance for the company

13
 Autonomous Maintenance

Planned Maintenance

Focused Improvement

Early Equipment
Management
TPM Goals:

Quality Maintenance

5S & Visual Management

Education & Training
Eight Pillars (Strategies) of TPM

Zero Defects, Zero Breakdowns, Zero Accidents

TPM in the Office

Safety & Environmental

Management
14
TPM Pillars & Activities 1
Pillar Activities
Autonomous maintenance Operator involvement in regular cleaning, inspection,
lubrication, and learning about equipment to maintain
basic conditions and spot signs of trouble

Planned maintenance A combination of preventive, predictive, and proactive

maintenance to avoid losses, and planned responses
to fix breakdowns quickly

Focused equipment and Measure of equipment- or process-related losses and

process improvement specific improvement activities to reduce the losses

Education and training A planned program for developing employee skills and
knowledge to support TPM implementation

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Module. 11

Total Productive Maintenance

2
Basic definitions
Uptime Part of total available time during which an equipment, machine, or system is
either fully operational or is ready to perform its intended function. Opposite
of downtime.

Downtime Part of total available time during which an equipment or machine was unable
to continue operations or was not ready to perform its intended function,
mainly due to the breakdowns. Opposite to uptime.

Breakdown Production is stopped. The process of failing to function or operate normally.

Breakdown is the stoppage lasting over 5 minutes. It requires intervention of
specialists (maintenance technicians), and necessary research before re-start.
Usually, the reasons are identifiable and systematically registered.

Micro-stoppage Production is not stopped. Usually short duration and high frequency. Strongly
involve operators. Work continues without identifying and eliminating of root
causes that are not registered.

17
 Understanding TPM

Maintenance Production
Team team
Preventive & Predicitive Autonomous
Maintenance Maintenance

Breakdown Micro-stoppages
elimination elimination

TPM
18
Team Roles for Maintenance
“I only repair the machines ..”
New Roles of Maintenance
Preventative Actions:
 Work as part of a Team
 Implement and adhere to a planned
maintenance schedule
 Pass equipment knowledge onto
operators
 Use predictive techniques
 Develop routine maint. standards
 Increase own skills with enhanced
training
Corrective Actions:
 Study and analyse causes of downtime
 Carry out repairs efficiently and
effectively
 Upgrade and overhaul old plant
Equipment Improvements:
 Investigate and implement simple
improvements to eliminate root causes
of downtime
 Involvement in capital purchase
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 TPM Program
GOAL
World
Class
Manufacturing

Predictive Maintenance
Phase 3 Maintenance Prevention

Autonomous Preventive Skill

Phase 2 Maintenance Maintenance Improvement

Data Collection OEE

TPM
Phase 1 Teams
& Analysis Measurement
System

Management TPM
Phase 0 Support/Employee Implementation
Training &
Education
Involvement Strategy

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Module. 11

Total Productive Maintenance

3
TPM Key Components

 Preventive Maintenance - using schedules or planned maintenance

to ensure the continuous, smooth operation of equipment.

 Autonomous Maintenance - involving production employees in the

total machine maintenance process. This goes well with 5S.

 Predictive Maintenance - determining the life expectancy of

components in order to replace them at the optimum time.

 Maintenance Prevention - designing or selecting equipment that will

run with minimal maintenance and is easy to service when necessary.

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Preventive Maintenance

Preventive maintenance:

 Daily maintenance:
 cleaning, checking, lubricating and tightening to prevent
deterioration.

 Most of these activities are covered by autonomous

maintenance, and are performed by the operators.
Nevertheless, those activities need to be scheduled and
treated as planned maintenance activities.

 Periodic inspections or equipment diagnosis to

measure deterioration.

 Restoration to correct and recover from

deterioration.
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Goals of a Suggestion System

Effects Tangible & Intangible Results

3

Improvement of Performance
Development
2 on the Job
of Skills

Development & Activation of the

1 Participation Organizational Structure

Source: Kaizen Teian 1 - Developing Systems for Continuous Improvement

Through Employee Suggestions
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Goals of a Suggestion System

Development of Skills Improvement of Performance

on the Job

Participation Development & Activation

of the Organizational Structure

Effects Tangible & Intangible Results

Source: Kaizen Teian 1 - Developing Systems for Continuous Improvement Through

Employee Suggestions
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One-Point Lessons as a Cascading Training Tool

Team members are responsible for

training each other

Teaching promotes effective leadership

and accountability

One-point lessons – a teaching tool that

is short and to the point

Follow up to see what has been taught is

practiced

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Activity Board

 Activity board is a visual tool to guide teams to action

 Basic elements of problem solving:
1. What are we going to do? (Theme)
2. Why are we going to do it? (Vision)
3. How far are we going to go? (Targets)
4. How are we going to do it? (Method)
5. What is the sequence and timing of actions? (Schedule)
6. Who does what? ( Roles)
7. What results do we expect? (Assessment)

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Module. 11

Total Productive Maintenance

4
Equipment Loss
Diagnosis & OEE
Introduction to OEE

 OEE (Overall Equipment Effectiveness) is a metric that

identifies the percentage of planned production time that is
truly productive

 How to understand OEE score?

 An OEE score of 100% is perfect production (not attainable in reality)
 An OEE score of 85% is world class for discrete manufacturers
 An OEE score of 60% is fairly typical for discrete manufacturers
 An OEE score of 40% is not uncommon for manufacturers without TPM
and/or lean programs

What is your organization’s OEE score?

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OEE and NON-OEE. Example Data
How close a piece of equipment is producing sellable product at the theoretical
processing speed over the entire period of time observed

Example Data Non-Operation time

22%
Scheduled Downtime (PM)

Unscheduled Downtime
44%
Yield loss (Rework & Scrap)
9%
Idle (Wait for Operator/
Starvation/Blockage)
Speed loss

13% OEE

4% 4% 4%
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 Understanding OEE. Definition
100% OEE
Total operating time
Scheduled
A Available time unavailable time

Failure &
B Running time Idle time • Programmed breaks
• Planned maintenance
• Meetings & HR

C Theoretical production
• Breakdowns > 5 minutes
• Overrun on planned
Speed losses & downtime
D Real production Micro-stoppages
• Changeovers & Trials
• External causes

• Operational speed lower

than the nominal
E Real production • Micro-stoppages < 5 min

F Good production Rejects & Rework Lost capacity %

• All quality defects

incl. products on-hold

OEE = B/A x D/C x F/E

Availability Performance Quality
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Six Big Equipment Losses

OEE

Availability Performance Quality

Setups & Reduced Minor Stops Defects & Startup &

Breakdowns
Adjustments Speed & Idling Rework Yield Loss

Source: Japan Institute of Plant Maintenance (JIPM)

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Breakdown Losses

 Largest of the 6 major equipment losses

 Caused by equipment defects which require any kind of
repair. Examples:
 Tooling failures
 Unplanned maintenance
 General breakdowns
 Equipment failure
 Losses consist of downtime with labor and spare parts
required to fix the equipment
 Magnitude is measured by downtime

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Strategies for Zero Breakdowns

 Restore equipment
 Maintain basic equipment conditions
 Adhere to standard operating
procedures
 Improve operator maintenance skills
 Don’t stop at quick fixes
 Correct design weaknesses
 Study breakdowns relentlessly

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Module. 11

Total Productive Maintenance

6
Planned Maintenance
How do you maintain your equipment?

Fix it and forget it

36
 Planned Maintenance
Objective:
To increase equipment reliability and minimize maintenance cost by
reducing breakdowns and developing efficient maintenance
methods

 Benefits:
 Significantly reduces instances of unplanned downtime
 Enables most maintenance to be planned for times when
equipment is not scheduled for production
 Reduces inventory through better control of wear-prone
and failure-prone parts

37
Planned Maintenance

 How to achieve the natural life cycle of individual machine

elements:

 Correct operation
 Correct set-up
 Cleaning
 Lubrication
 Retightening
 Feedback and repair of
minor defects
 Quality spare parts

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 Planned Maintenance: Main Activities

Improvement of Equipment Improvement of Maintenance Skills

 MTBF  MTTR

Preventive Maintenance Specialized maintenance skills

Corrective Maintenance Equipment repair skills

Maintenance Prevention Inspection and measurement skills

Breakdown Maintenance Equipment diagnostic skills

Support for Autonomous Maintenance Develop new maintenance

technologies

39
Terminologies

 MTBF (Mean Time Between Failures)

 MTBF is a basic measure of reliability for repairable items. It can be
described as the number of hours that pass before a component,
assembly, or system fails. It is a commonly-used variable in reliability
and maintainability analyses.

 MTTF (Mean Time To Failure)

 MTTF is a basic measure of reliability for non-repairable systems. It is
the mean time expected until the first failure of a piece of equipment.
MTTF is a statistical value and is meant to be the mean over a long
period of time and large number of units.

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Module. 11

Total Productive Maintenance

7
Focused Improvement
 Focused Improvement

Focused Improvement
Objective:

To achieve regular, incremental improvements in equipment

operation by small groups
of employees working together proactively so as to continually
improve OEE performance

 Benefits:
 Recurring problems are identified and resolved by cross-
functional teams
 Combines the collective talents of a company to create an
engine for continuous improvement

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 Focused Improvement

Focused Improvement - Target

 Achieve and sustain zero losses - OEE

 Unplanned downtimes
 Minor stops
 Measurement and adjustments
 Defects
 It also aims to achieve 30% manufacturing cost reduction

43
 Focused Improvement

Examples of Focused Improvement Events

 Relocating gauges and grease fittings for easier access

 Making shields that minimize contamination

 Centralizing lubrication points

 Making debris collection accessible

44
 Focused Improvement

Improving OEE Through Kaizen Event

Set TPM
Targets

Report
results and Go after
Have them the targets
recognized with everyone’s
help

Achieve Analyze
and verify breakdowns,
targets suggest
improvements
Track and
record
performance

45
 Safety & Environmental Management

Safety & Environmental Management

Typical causes for
accidents in production
Unintentional unsafe acts
are the leading cause of
accidents in most work
places in industry.

Properly establishing
standardized work and
following standardized
work can prevent injuries.

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Module. 11

Total Productive Maintenance

9
TPM Implementation
 TPM Implementation
TPM Implementation Master Plan
 Define a 3-5 year TPM Master Plan
 More detailed plan for the first 3 years
 3 major deployment phases:
 Preparation
 Implementation
 Expansion

 Suggested focus for first 3 years:

 Education & Training
 Autonomous Maintenance
 Planned Maintenance
 OEE / Focused Improvement

48
 TPM Implementation
12 Steps of TPM Implementation
1. Announcement to introduce TPM
2. Introductory education campaign for the workforce
Preparation 3. TPM Promotion (special committees)
4. Establish basic TPM policies and goals
5. Preparation and Formulation of a master plan

Kick-
6. Invite customers, affiliated companies and subcontractors
off

7. Develop an equipment management program

8. Develop a planned maintenance program
Implementation 9. Develop an autonomous maintenance program
10. Increase skills of production and maintenance personnel
11. Develop early equipment management program

Stabilization 12. Perfect TPM implementation and raise TPM levels

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 Sustaining TPM
How to Sustain TPM

 Engaging employees

 Aim for early success

 Providing active leadership
 Share success stories
 Rewards and recognition
 Continuously improve OEE
 Evolving the TPM initiative over time and integration with
Lean

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© Lean & Mean Consulting. All rights reserved. 2016
51