Total Productive Maintenance

TPM Training Agenda

TPM History, benefits and typical results
Definition and 5 Pillars of TPM
The 6 Big Losses
Autonomous Maintenance
Maintenance Prevention
Setting Standards & Sustaining the Benefits
TPM and Safety
The Advisory Team
Equipment Improvement Teams (EITs)
TPM vs. 5S
Summary of TPM topics

2
 Origins of TPM
Breakdown maintenance (RTF) - historical
Preventive Maintenance concept introduced in1951
Productive Maintenance introduced later
Included
Preventive maintenance
Improvement-related maintenance
Maintenance prevention
Still primarily maintenance department
Never achieved zero breakdowns or
defects

3
 Origins of TPM
Total Productive Maintenance
Brought operators into the picture
Small group activities
Teamwork between operators and
maintenance
Involvement & support throughout the
company

4
 No Tolerance for Breakdowns

Equipment breakdowns impact

Customer service
Production costs
Maintenance costs
Effectiveness of manufacturing
cells or flow lines
Breakdowns result in chaos

5
 The Last 50 Years
In the 1950s, about 70% of durable
goods sold in the world were made in the
U.S. today << 10%
In the 1950s, there were over 25 U.S.
television manufacturers by the early
1990s, only 1 (Zenith) today??
In the 1950s, the largest growing job was
in manufacturingnot the case today!!

Most manufacturing industries are fighting a war

to survive! 6
 Benefits of TPM to the Company

Improved plant productivity and

capacity
Lower operating costs
Improved equipment lifespan
Better ability to satisfy customers

Bottom Line: TPM increases

long-term viability
7
 Benefits of TPM for Operators &
Maintenance Personnel
Increased skills through additional
training
Better job satisfaction
Operators More involvement in solving
annoying equipment problems
Maintenance More challenging work
Better job security

8
 Typical TPM Results

Overall equipment effectiveness up

25-65%
Quality defects down 25-50%
Maintenance expenditures down 10-
50%
Percent planned vs. unplanned
maintenance increased 10-60%

9
 Definition

TPM is a company-wide system developed to

maintain, monitor, and improve all capital
assets of a company. For production it is a
system that maximizes equipment
effectiveness and maintains product flow.
TPM is not just about maintenance. It is about
getting the most overall benefit from your
equipment over the life of the equipment.
TPM will not be an overnight success.
Implementing it throughout a plant correctly will
take several years.

10
 Shift in Attitudes

Operator Maintenance Operator Maintenance

I use I maintain & We maintain

I fix

Conventional TPM
11
 5 Pillars of TPM

1. Improvement activities designed to

increase equipment effectiveness (OEE)
2. Autonomous maintenance program
performed by equipment operators
3. A planned maintenance system
4. Training to improve operation &
maintenance skills
5. Effective new equipment design and
startup
12
 TPM Emphasizes Prevention

Three Principles of Prevention

1. Maintain normal conditions
2. Early discovery of abnormalities
a) Operator
b) Maintenance
3. Prompt response

13
 The Six Big Equipment Losses

1. Breakdowns
2. Setups and adjustment
3. Idling and minor stoppages
4. Speed
5. Quality defects and rework
6. Start-up (loss of yield)

14
Overall equipment effectiveness = Availability x Performance rate x Quality rate
(OEE)

Breakdown
Setup and adjustment
Others Idling & minor stoppages Quality defects & rework
Reduced speed Start-up yield
 Operation time (Scheduled time available Downtime)
Availability = ______________________________________________ x 100

Scheduled time available

processed amount x ideal cycle time

Performance rate = _____________________________

Operation time

Quality rate = Amount good / amount produced

 Improving OEE

1. Measure the extent of the 6 big losses

2. Analyze the causes (but focus your
efforts )
3. Develop solutions & create an
improvement plan
4. Set targets and estimate the benefits to
OEE
5. Carry out the plan
6. Establish measurements to monitor results
7. Repeat as necessary
17
 Eliminating Breakdowns

Workplace Conditions Contribute to

Losses
Filthy equipment
Oil and lubricant leaks
Moving parts encrusted with raw materials or debris
Disorderly wiring, hoses, etc.
Equipment mechanisms hidden or difficult to access
Workplace disorder
A belief that conditions cannot improve

18
 Eliminating Breakdowns

Why machines fail

Disregard for basic needs
(housekeeping, lube..)
Incorrect operating conditions
Lack of skill or knowledge of operator
Machine deterioration
Routine
Accelerated
Design deficiency

19
 Eliminating Breakdowns

Two kinds of breakdowns

Function loss (function completely lost) -
Sporadic
Function reduction (works, but with loss
of speed or quality) - Chronic
Two kinds of breakdown maintenance
Planned (pre-emptive)
Unplanned (firefighting)

20
 Autonomous Maintenance

The principal way production workers

participate in TPM
Purpose
1. Brings production & maintenance people
together to slow routine deterioration
and halt accelerated deterioration
2. Helps operators learn more about their
equipment (the cause and effect)
3. Prepares operators to be active partners
with maintenance and engineering in
improving equipment performance and
reliability

21
 Steps to Implementing Autonomous
Maintenance
Step 1: Initial cleaning and inspection
Step 2: Eliminate sources of
contamination and inaccessible areas
Step 3: Develop and test cleaning,
inspection, and lubrication standards
Step 4: General inspection training
and inspection procedures
Step 5: Conduct autonomous general
inspections

22
 Steps to Implementing Autonomous
Maintenance
Step 6: Organize and manage the
workplace
Step 7: Ongoing autonomous
maintenance and continued
improvement

23
 An advanced Improvement
method
Maintenance Prevention
Design-stage activities aimed at making
new equipment reliable, easy to care
for, and user friendly

24
 Sustaining TPM

Audits
Visual activity boards
Team charter
Team activities, goal, schedule, and progress
Cleaning, inspection, and lubrication
standards
Workplace organization standards
Trend charts for each of the big 6 losses
Inspection reports
Audit results
Before and after photos

26
 TPM and Safety
Safety is the cornerstone of
production activities
Accidents usually occur when unsafe
behavior is combined with
unsafe conditions
For every major accident there are
29 minor accidents and 300 near misses
Safety should always be the #1 priority

27
Setting Up a TPM Structure

EIT
EIT EIT
TPM
Advisory Mgmt
Team
EIT EIT

EIT
28
 Advisory Team - Responsibilities

Guide & champion TPM implementation

Assess current equipment OEE and
develop a process for measuring the 6
big losses
Develop a TPM master plan
Set plant-wide standards for TPM
implementation
Monitor and evaluate progress
Serve on EITs
29
 Equipment Improvement Teams -
Responsibilities
Return equipment to near new condition
Investigate and reduce the big 6
equipment losses
Transfer routine maintenance skills to
operators
Set standards for routine maintenance
and inspections by operators
Organize the work area for more
effective/efficient maintenance

30
 Setting Goals for Your TPM
Program
Short term 12 months
Establish an autonomous maintenance
program for x machines
Increase OEE by y% within for
individual work centers
Long term Reach a plant OEE of
85% within 3 years (world class is
considered about 85%)

31
 Comparing TPM to 5S

5S emphasizes
Productivity of workers
Organizing and visual indicators
TPM emphasizes
Effectiveness of equipment
Partnership between maintenance &
production
Reducing lifetime equipment costs
Both emphasize
Initial cleaning and repair
Safety
32
Shift in Equipment Maintenance
Activities

FROM THIS
to
THIS
Breakdown
Predictive
Planned repair Planned repair
PM PM
Breakdown Autonomous

33
 Review of TPMs benefits

For the company

Higher Overall Equipment Effectiveness
Less firefighting to repair machines
Lower operating costs
Better able to meet commitments to
customers
Improved ability to compete in the world
marketplace

34
 Review of TPMs benefits

For employees
Less pressure on maintenance for urgent
repairs
Less pressure on production to recover from
breakdown losses
Better cooperation between maintenance,
production, and other departments
Reduced chance of accidents
Higher job satisfaction
Improved job security
35