Total Productive Maintenance

TPM
Overview

Slide 1
 TPM as a Lean Initiative

• Competitive costs require

– Spending control
– Defect control
– Downtime reduction

• TPM = Total Productive Maintenance

– Proactive (with all employees involved)
– Preventive
– Predictive
– Planned

Slide 2
 Why Change?

• ACTIONS:
– Reduce defectives / scrap
– Reduction of lost production time
– Lowest possible cost by reducing waste

Slide 3
 Lean System

Peak Performance
Pull system / flow production
Rapid Changeover / Customer-driven lot size
Continuous Waste Reduction
Lean Measures

5S Standardized
Visual TPM Work
Factory

Variation reduction / Six Sigma

In-Station Process Control
Leadership by Example & Commitment
Employee Involvement & Mutual Respect
Slide 4
 7 Wastes

• Transportation
• Excess production
• Added processes
• Motion

• Waiting
• Inventory
• Non-conformance (defectives)
Slide 5
 Causes of Waste
• Excess Manning
– Poor layout and material presentation
– Rework and extra processes
– Inconsistent / inefficient work methods
• Excess Downtime
– Tooling condition
– Unreliable equipment
– Long changeovers
– Incapable process
• Defectives - Rework or Replace
– Incapable processes or process not
compatible with customer expectations or
design spec (design for mfg)
– Tooling condition
– Operator methods and errors
Slide 6
 Causes of Waste
• Excess Manning
– Poor layout and material presentation
– Rework and extra processes
– Inconsistent / inefficient work methods
• Excess Downtime
– Tooling condition
– Unreliable equipment
– Long changeovers
– Incapable process
• Defectives - Rework or Replace
– Incapable processes or process not
compatible with customer expectations or
design spec (design for mfg)
– Tooling condition
– Operator methods and errors
Slide 7
 Effective TPM Eliminates 5 Losses

1. Equipment breakdowns
2. Defects, scrap, and rework
3. Safety Issues
4. Mini stoppages
5. Reduced speed

Slide 8
 What is TPM??

TPM is a Lean tool to optimize the effectiveness of

manufacturing equipment and tooling.

1. Starts with 5S / Visual Factory

2. Builds a comprehensive Downtime Database by
cause, frequency, and duration
3. Predicts and prevents downtime by PM system
4. Expands role of Operator as first point of early
warning and prevention
5. Develops Professional Maintenance skills

Slide 9
 Operator Autonomous Maintenance

Seven Steps Aut. Mgt. 77

of TPM Standardization 66
Autonomous Inspection
55
General Inspection 44
Initial Standards
33
Countermeasures for Contamination
22
Initial Clean-up
11
Slide 10
 TPM is Planned, Predictive, & Preventive

1. Starts with 5S / Visual Factory

2. Builds a comprehensive downtime data
base by cause, frequency, and duration
3. Predicts and prevents downtime by PM
system
4. Expands role of Operator as first point of
early warning and prevention
5. Professional Maintenance

Slide 11
 5S Workplace

A safe, clean, orderly workplace is

fundamental to quality, efficiency, and teams

Sort (organize)
Shine (clean)
Set in order (make orderly and neat)
Standardize (visual place for everything)
Sustain (maintain the system)

Slide 12
 TPM starts with 5S

• You can’t see problems clearly when

the workplace is in disarray
• Cleaning and organizing the workplace
helps the team to uncover problems
• Making problems visible is the first step
of improvement
• Clean machines and workplace create
pride & Safety

Slide 13
 Downtime Visual Controls

• Visual or audio alerts

– Abnormality obvious at a glance (e.g. stoppage,
reject, control fault)
– Alerting Maint and team leaders
– Provide real time “scoreboard” for employees
• Machine down light visible from aisle
• Production status board (e.g. actual counts vs. goal)
• Scrap counts and downtime minutes
• Located in clear view in shop (not in control room)
• Simple, self regulating, & employee managed

Slide 14
 TPM is Planned, Predictive, & Preventive

1. Starts with 5S / Visual Factory

2. Builds a comprehensive
downtime data base by cause,
frequency, and duration
3. Predicts and prevents downtime by PM
system
4. Expands role of Operator as first point of
early warning and prevention
5. Professional Maintenance

Slide 15
 Downtime Database
• Categorize at a minimum by Equip, Tooling, C/O, Other
• Segmented bar graph for E-T-O lost time
• Subcategories for Equip (e.g.)
– Hydraulic / pneumatic
– Mechanical / lubrication
– Electrical / controls
– Shot-end components
• Subcategories for Tooling (e.g.)
– Slides
– Cores
– Inserts
– Ejector pins
• Subcategories for Other (e.g.)
– Operator error
– Materials
Slide 16
 Minimum Downtime Tracking

Downtime by Cause 3500 ton Bay

Other (avg min/shift per Machine)

120
Tools
100

80
O
Minutes 60
T
40 E

20
Equip
0
1Q02 2Q02 Jun Jul Aug Sep Oct Nov Dec

Slide 17
 TPM is Planned, Predictive, & Preventive

1. Starts with 5S / Visual Factory

2. Builds a comprehensive downtime data
base by cause, frequency, and duration
3. Predicts and prevents downtime
by PM system
4. Expands role of Operator as first point of
early warning and prevention
5. Professional Maintenance

Slide 18
 Predictive Maintenance Tools
• Rate/hr vs. target or historical normal output (B/W)
• Database
– MP2 / maintenance history
– statistical probability (frequency & duration)
• Physical prediction of impending failure
– Sound (bearing)
– Temperature (cooling water)
– Flash (core pins)
– Shot monitoring system
– SPC on part geometry
– Hydraulic pressure (ejector pins)
– Spindle loads (amps)
– Fluids / Lubrication analysis (milipore)
– Vibration Signature Analysis
Slide 19
 Preventive Maintenance System
• History of downtime by major machine & tool
– Downtime measurement & tracking
– Mean Time Between Failures
– Average downtime
– Pareto of causes at component level (eg L/S or temp sensor)
– Cost to maintain
• Develop PM cards based on frequency of failure and magnitude of
average lost time (start small & grow)
– Limit & prox switches
– Shot tip / sleeve
– Critical frame and cylinder mounting bolts
– Expendable tools
– Valves, hoses, packing, seals
• PM’s have instruction, schedule/frequency & sign-off
– PM’s / repairs done in window of opportunity when machine is down
– Cycle count or date based execution of PM’s (eg cutter change)
– PM status visual (work completed / not completed)
Slide 20
 TPM is Planned, Predictive, & Preventive

1. Starts with 5S / Visual Factory

2. Builds a comprehensive downtime data base by
cause, frequency, and duration
3. Predicts and prevents downtime by PM system
4. Expands role of Operator as first point
of early warning and prevention
• One point lessons for operator awareness
• Creates OMP (Operator - Maintenance
Partnership)
• Operator performs checks, problem
solving, and improvements
5. Professional Maintenance

Slide 21
 TPM

Production Operators
• Clean & Check
• Observe
• Categorize
Active
Production Planning Quality Engineers
& Control
Planned • Standards &
• Schedule P.M. Maintenance Calibrations
Process
Manufacturing Engineers
• Equipment Planning
• Equipment Studies

Slide 22
 OMP - Operator Maintenance Partnership

• Operator training in TPM

TPM
• Operator basic equip inspection
& tooling checks
• Operator basic cleaning
• Operator lubrication check
• One point lessons (capture
knowledge)
• TPM Board & TPM Tags
(proactive operator involvement)

Slide 23
 TPM Tag System

• Problem communication tool to and from

maintenance, tool room, and production
– Identify abnormal machine conditions
• Record problem discovered by operator
• Record problem found during scheduled PM
– Status tracking system of requested repairs
– TPM visual management tool (hang tags)
– Repair history for future problem solving
• TPM Tag used for recording problem & fix
– Blue Tag-Operator or Maint responsible to repair
– Red Tag- Safety-related request (priority)

Slide 24

Operator/Supervisor
1. Abnormality Identified
2. Fill out Tag Red= Safety
Blue= Prod/Maint
3. Hang C-tag as close to the defect
as possible
4. Hang A &B Tags on the TPM Tag
status board by Machine location and
area of responsibility to correct.
7. Operator/Supervisor check to see
if work was done.
8. If OK, Operator/ supervisor
removes C tag from machine and
places ABC tags in Completed box. If
not OK, tags stay and maint is
contacted. Contact noted on tag.
Tag Process
Production Management
9. Production management reviews
the information. Also reviews the
comments and takes actions if
required. Places tag in history file box
located in the office
Maintenance
5.Maintenance evaluates problem. If
fixed immediately go to 6. If parts or
time needed, maint pulls A tag from
board. The A tag is MWO. The B
tag is posted on the Maint WO
status section of the TPM Board with
est. timing.
6.After work is completed,
maintenance completes back side of
A tag and places both the A & B tag
in the work completed box

Tag information is recorded and reviewed for continuous improvement of PM

database by Production and Maintenance; Repeat operator tags may indicate
Maint needs to investigate.

Slide 25
 TPM is Proactive, Predictive,
Preventive & Planned

1. Starts with 5S / Visual Factory

2. Builds a comprehensive downtime data
base by cause, frequency, and duration
3. Predicts and prevents downtime by PM
system
4. Expands role of Operator as first point
of early warning and prevention
5. Professional Maintenance

Slide 26
 Professional Maintenance

• Equip Safety
• Skill building
• Cross-training
• Area Maintenance
• MRO stores
• Maint Mgmt System
• Down alarms
• Radios
• Planned PM
Slide 27
Operator Autonomous Maintenance

7 Steps

T P M

Aut. Mgt. 77
Standardization 66
Autonomous Inspection
55
OIL
General Inspection
44
Prepare Temporary Standards
33
Countermeasures for Contamination
22
Initial Clean-up
11
Slide 28
 TPM
Initial Focus

TPM I TPM II
Step 1 Step 4
5S Step 2 Step 5
Step 3 Step 6
Step 7

prerequisite for TPM I

Slide 29
 STEP 3: Prepare Temporary Standards
This step is to enhance the equipment reliability
& maintainability.
• Temporary Check Sheet For Clean-Up,
Lubrication, Start-up, and Shut-down:
– What items need to be done
– Who will perform the check
– How often to check
– Where the location is to be checked
– What to use for the inspection or cleaning
– Target time to complete the task

Slide 30
 TPM Summary
• TPM = Total Productive
Maintenance
– Proactive (all employees
involved) Peak Performance

– Preventive
– Predictive Continuous Waste Reduction
– Planned
• TPM is an integral part 5S Standardized
of Total Quality Visual TPM Work
production System Factory

Slide 31
TPM is a Lean tool for
Quality and
Productivity

Slide 32