Lorraine Fraser, P.Eng., M.Eng.

, MBA, CQE, CQA, CQM/OE, CSSBB

ASQ Toronto Section November 11, 2015

 Introduction

To TPM
Benefits of TPM
What does TPM look like?
How to implement TPM
How to Sustain TPM
Summary
Questions

TPM

The 7 Wastes

TPM

TPM stands for Total Productive Maintenance.

TPM Development was first published in Japan in 1982. Since then new
concepts and refinements have been added to the basic program.
TPM first took root in the automotive industry. More recently it has been
introduced in consumer goods, electronics, plastics and many others.
Administrative and support departments such as product development
and sales also use TPM.
Production output and rate, quality, safety, and the environment depend
almost entirely on the state of equipment.
TPM is a method for continuously improving the effectiveness of
production equipment and processes.

TPM

World Class Operating Excellence is Achieved using optimized work standards with
group activities of associates who demonstrate ownership

Office

People

Logistics

Early Equipment
Management

Productivity

Training & Development

Quality Management

Cost

Environment, Health &

Safety

Planned Maintenance

Quality

Autonomous Maintenance

Improvement

Focused

Safety

5S & Teams
TPM

 Guarantees Significant Tangible Results - Results achieved include

reduction in equipment breakdowns, lower quality defects and claims,
higher productivity, shrinking inventory, lower number of accidents.
P net productivity up by 2x
Qprocess defect rate down 90%
Cproduction costs down 30%
Dproduction and work in process inventories halved
Saccidents 0
Mimprovement suggestions up by 10x
Transforms the Plant Environment a rusty plant can be reborn as a
pleasant, saffe working environment.
Transforms the Employees - As concrete results are achieved,
workers become motivated. Associates begin to think of TPM as part
of their job.
TPM

Benefits of TPM

Customers and visitors are impressed by these changes

Confidence in the plants products increases.
Overall Equipment Effectiveness (OEE) is maximized through
zero breakdowns and failures, zero accidents, zero defects
through total employee involvement.
Equipment reliability and maintainability as contributors to
quality and productivity is increased.
TPM culture promotes zero loss activities.
TPM involves all associates from the shop floor to top
management.

TPM

Benefits of TPM

TPM

TPM

What Does TPM Look Like?

Machine Operators are trained to do much of the maintenance

operations, and its part of their Standard Work

TPM

What Does TPM Look Like?

Necessary tools are readily available

TPM

What Does TPM Look Like?

Equipment is modified such that it easy to keep clean, easy

to see when maintenance is required.

Befor
e

After

TPM

What Does TPM Look Like?

Happy and Engaged Associates

TPM

How To Implement TPM?

1. Formally announce decision to introduce TPM.

2. Conduct TPM introductory education & publicity campaign
3. Create a TPM promotion organization.
PlantManager

CompanywideTPMpromotion
Committee

SectionManagers

PlantTPMPromotion
Committee

GroupLeaders

SectionTPMPromotion
Committee

ShopFloorAssociates

PMcircles

TPM

How To Implement TPM?

4. Establish basic TPM policy and goals.

Policy example:
Establish a profitable corporate constitution, promote TPM

Establish numerical goals examples:

Zero breakdowns,
Zero defects, seek to maximize overall equipment effectiveness.

TPM

How To Implement TPM?

5. Draft a master plan for implementing TPM.

To formulate a master plan for implementation decide what
activities must be pursued to achieve the TPM goals.
The core TPM activities are:
Focused improvement
Autonomous Maintenance
Planned Maintenance
Education and Training
Early Equipment Management
Quality Maintenance
Administrative and support department activities (Logistics & Office)
6.Kick off TPM initiative should be designed to cultivate an atmosphere
that raises morale and inspires dedication.
TPM

How To Implement TPM?

7. Build a corporate constitution designed to maximize production

effectiveness.
8. Build an early management system for new products and
equipment.
9. Build a quality maintenance system.
10. Build an effective administration and support system.
11. Develop a system for managing health, safety, and the
environment.
12. Sustain full TPM implementation and sustain levels.
The first pillars to implement are the Focused Improvement, Autonomous
Maintenance, Planned Maintenance, & Training and Development
Pillars
TPM

How To Implement TPM?

TPM

How To Implement TPM?

The Eight Major Plant Losses:

Shutdown loss
Production adjustment loss
Equipment failure loss
Process failure loss
Normal production loss
Abnormal production loss
Quality defect loss

Loss deployment
All pillars are responsible
for analyzing the loss
deployments for their
losses.
As losses are reduced,
the priority of teams
selected will change

Reprocessing loss
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How To Implement TPM?

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How To Implement TPM?

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How To Implement TPM?

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How To Implement TPM?

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How To Implement TPM? |

TPM

How To Implement TPM?

1. Select Equipment to work on.

Equipment that is giving you problems with
Unplanned downtime
Excessive quality problems
Excessive repair costs
Premature end of life failures
Running slower than design to prevent breakdowns
2. 5S Event.
Improve ability to perform regular inspections
Allow the discovery of potential problems
Log problems and potential problems and develop an
immediate action plan
Mark all lubrication, fluid connections and directions, etc
Paint equipment
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How To Implement TPM?

3. Defining Machine Operator Tasks

Develop Standards and Checklists Cleaning,

Lubrication, Visual Checks, Procedures to keep
equipment new.

4.MakeMachneOperatormaintenancetaskseasier/quicker
Easytoseewhenthingsneedtobemaintained
Lubricationneedsbecomeobvioustooperator
Routinecleaningoperationseasier
Machinedisassemblyminimized
Automatemaintenancewhenpossible
Clearsignalswhenmaintenanceisneeded
Ensureoperatortrainingiscomplete
FinalizeChecklistschedules

TPM

How To Implement TPM?

Define Maintenance Tech Tasks

Provide Tech support to operator questions

Provide clear communication path
Spare Parts Program
Equip Manufacturer recommendations
Breakdown History Data
Eliminate Equipment Deterioration
Scheduled general inspections
Equipment overhauls triggered by checklists
Identify and Resolve Chronic Problems
Breakdown history log
Root cause analysis methods including 5 Whys
TPM

How To Implement TPM?

Define Maintenance Tech Tasks

Develop and Analyze Equipment History

Plot failure history
Correlate with Equipment Quality Performance
Determine Equipment Parameters That Predict
Failure
Use information from equipment manufacturer
Oil, vibration, temperature analysis
Develop Equipment Monitoring Systems
Ensure appropriate accuracy and tolerance
Lease equipment to ensure usability before
purchase
TPM

How To Implement TPM?

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How To Implement TPM?

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Benefits of TPM

Reactive Maintenance if it is not broken do not fix it.

Preventive Maintenance time or machine cycle based
maintenance functions
Predictive Maintenance functions on feedback that
something needs to be done.

TPM Autonomous Maintenance & Planned Maintenance

TPM

 Loss

methologies in use:

Use of a QA Matrix which is a tool that prioritizes

actions against the sources of defects in a process.
The matrix correlates defect modes with machine
parameters. The matrix identifies the location of Q
points the points that need to be controlled to
eliminate defects.
Defect Reduction Methodology
CpK Improvement Methodology

How to Sustain TPM?

Measuring progress is key (through Steering Committee)

The Primary Measurement tool is OEE (Overall Equipment
Effectiveness is measures.
OEE = Equip Availability X Performance Efficiency X Quality Rate
Build strong teams at every level and staff a promotion office
Track projects weekly from date of closure, up to 6 months then
monthly for the next 6 months. When a project looses traction,
the pillar team analyzes the anomaly & take corrective actions as
needed. Once a project is sustained for a year, it can be
removed from the KPI tracker.
Use management indicators that show everyone (at every level)
what concrete progress is being made and motivate their
continued involvement.
TPM

How to Sustain TPM

Recognized as the Global leaders in TPM

Two audits take place with Japanese auditors
In the face of growing competition, the award drives a continuous
culture of improvement the focuses on cost reduction & improvement
in efficiencies

TPM

Summary

TPM

Summary

TPM is a method for continuously improving the

effectiveness of production equipment and
processes by improving On Demand availability of
the equipment, through improved maintenance.
The primary focus is on involving machine
operators in routine maintenance, and making that
maintenance easily seen, easily done, and
effective. This only happens through involvement
of every single associate in every department in a
factory.

TPM

Questions

TPM