Partners for Creative Solutions, Inc. 36 Deerfield Rd, Shrewsbury, MA 01545 508 845-1546 tmcbride@pcs-info.


Total Productive Maintenance

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Partners for Creative Solutions, Inc.

TPM Training Agenda
TPM ± History, benefits and typical results Definition and ³5 Pillars´ of TPM The ³6 Big Losses´ Autonomous Maintenance Maintenance Prevention Setting Standards & Sustaining the Benefits TPM and Safety The Advisory Team Equipment Improvement Teams (EIT¶s) TPM vs. 5S Summary of TPM topics
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Partners for Creative Solutions, Inc.

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
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Partners for Creative Solutions. 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 Page. Inc. 4 .

No Tolerance for Breakdowns Equipment breakdowns impact  Customer service  Production costs  Maintenance costs  Effectiveness of ³manufacturing cells´ or ³flow lines´ Breakdowns result in ³chaos´ 5 Page. Inc.Partners for Creative Solutions. 5 .

«today << 10% In the 1950¶s. The Last 50 Years In the 1950¶s. the largest growing job was in manufacturing«not the case today!! Most manufacturing industries are fighting a war to survive! 6 Page.S.Partners for Creative Solutions. only 1 (Zenith) «today?? In the 1950¶s. 6 . television manufacturers «by the early 1990¶s. about 70% of durable goods sold in the world were made in the U. Inc. there were over 25 U.S.

Inc. 7 .Partners for Creative Solutions. 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 Page.

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 Page. Inc. 8 .Partners for Creative Solutions.

Typical TPM Results Overall equipment effectiveness up 25-65% Quality defects down 25-50% Maintenance expenditures down 10-50% Percent planned vs.Partners for Creative Solutions. 9 . unplanned maintenance increased 10-60% 9 Page. Inc.

 TPM will not be an overnight success. It is about getting the most overall benefit from your equipment over the life of the equipment. is not just about ³maintenance´.  TPM 10 Page. Definition TPM is a company-wide system developed to maintain. Implementing it throughout a plant correctly will take several years.Partners for Creative Solutions. Inc. monitor. and improve all capital assets of a company. 10 . For production it is a system that maximizes equipment effectiveness and maintains product flow.

Partners for Creative Solutions. Shift in Attitudes Operator Maintenance Operator Maintenance I use I maintain & I fix We maintain Conventional Page. 11 TPM 11 . Inc.

5.Partners for Creative Solutions. Improvement activities designed to increase equipment effectiveness (OEE) Autonomous maintenance program performed by equipment operators A planned maintenance system Training to improve operation & maintenance skills Effective new equipment design and startup 12 Page. 3. Inc. 2. 5 Pillars of TPM 1. 4. 12 .

Prompt response 13 Page. Maintain normal conditions Early discovery of abnormalities Operator b) Maintenance a) 3.Partners for Creative Solutions. TPM Emphasizes Prevention Three Principles of Prevention 1. Inc. 13 . 2.

5. The Six Big Equipment Losses 1.Partners for Creative Solutions. 3. 14 . Inc. 6. 4. Breakdowns Setups and adjustment Idling and minor stoppages Speed Quality defects and rework Start-up (loss of yield) 14 Page. 2.

Overall equipment effectiveness = Availability x Performance rate x Quality rate (OEE) Breakdown Setup and adjustment Others Idling & minor stoppages Reduced speed Quality defects & rework 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 .

7. Inc. 17 . Measure the extent of the 6 big losses Analyze the causes (but focus your efforts ) Develop solutions & create an improvement plan Set targets and estimate the benefits to OEE Carry out the plan Establish measurements to monitor results Repeat as necessary 17 Page. 3. 5. 6. 2.Partners for Creative Solutions. Improving OEE 1. 4.

etc. hoses. Equipment mechanisms hidden or difficult to access Workplace disorder A belief that conditions cannot improve 18 Page. 18 . Inc. Eliminating Breakdowns Workplace Conditions Contribute to Losses Filthy equipment Oil and lubricant leaks Moving parts encrusted with raw materials or debris Disorderly wiring.Partners for Creative Solutions.

lube.) Incorrect operating conditions Lack of skill or knowledge of operator Machine deterioration  Routine  Accelerated Design deficiency 19 Page.Partners for Creative Solutions. Eliminating Breakdowns Why machines fail Disregard for basic needs (housekeeping. 19 .. Inc.

Eliminating Breakdowns Two kinds of breakdowns loss (function completely lost) . 20 .Partners for Creative Solutions. but with loss of speed or quality) .Sporadic  Function reduction (works. Inc.Chronic  Function Two kinds of breakdown maintenance  Planned (pre-emptive)  Unplanned (firefighting) 20 Page.

21 Page. Helps operators learn more about their equipment (the cause and effect) 3. Inc. 21 . Autonomous Maintenance The principal way production workers participate in TPM Purpose Brings production & maintenance people together to slow routine deterioration and halt accelerated deterioration 2. Prepares operators to be active partners with maintenance and engineering in improving equipment performance and reliability 1.Partners for Creative Solutions.

Partners for Creative Solutions. 22 . Inc. and lubrication standards Step 4: General inspection training and inspection procedures Step 5: Conduct autonomous general inspections 22 Page. inspection. 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.

Inc.Partners for Creative Solutions. Steps to Implementing Autonomous Maintenance Step 6: Organize and manage the workplace Step 7: Ongoing autonomous maintenance and continued improvement 23 Page. 23 .

Inc. An advanced Improvement method Maintenance Prevention Design-stage activities aimed at making new equipment reliable. 24 . easy to care for. and user friendly 24 Page.Partners for Creative Solutions.

25 . how. inspection. Inc. when)  Standards for operator & maintenance personnel training Preventive Maintenance Program Predictive Maintenance Breakdown & Pre-emptive maintenance Maintenance Prevention 25 Page. fastener tightening and lubrication standards (what.Partners for Creative Solutions. who. TPM Standards Enhance Success Autonomous maintenance (plant-wide & localized)  Daily cleaning.

schedule. goal. 26 . Sustaining TPM Audits Visual activity boards  Team charter  Team activities. Inc. and progress  Cleaning. and lubrication standards  Workplace organization standards  Trend charts for each of the big 6 losses  Inspection reports  Audit results  Before and after photos 26 Page. inspection.Partners for Creative Solutions.

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 Page. 27 .Partners for Creative Solutions. Inc.

Setting Up a TPM Structure EIT EIT TPM Advisory Team EIT EIT 28 Page. 28 EIT Mgmt EIT .Partners for Creative Solutions. Inc.

Responsibilities Guide & champion TPM implementation Assess current equipment OEE and develop a process for measuring the ³6 big´ losses Develop a TPM master plan Set plant-wide standards for TPM implementation Monitor and evaluate progress Serve on EIT¶s 29 Page. Inc. 29 . Advisory Team .Partners for Creative Solutions.

Inc. 30 .Partners for Creative Solutions. Equipment Improvement Teams Responsibilities Return equipment to near new condition Investigate and reduce the ³big 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 Page.

31 . Inc.Partners for Creative Solutions. Setting Goals for Your TPM Program Short term ± 12 months  Establish an autonomous maintenance program for ³x´ machines  Increase OEE by ³y´% within for individual work centers Long term ± Reach a plant OEE of 85% within 3 years (world class is considered about 85%) 31 Page.

Inc.Partners for Creative Solutions. 32 . Comparing TPM to 5S 5S emphasizes  Productivity of workers  Organizing and visual indicators TPM emphasizes  Effectiveness of equipment  Partnership between maintenance &  Reducing lifetime equipment costs production Both emphasize  Initial cleaning  Safety and repair 32 Page.

Partners for Creative Solutions. Inc. Shift in Equipment Maintenance Activities FROM THIS to THIS Breakdown Predictive Planned repair PM Breakdown Planned repair PM Autonomous 33 Page. 33 .

Partners for Creative Solutions. Inc. Review of TPM¶s benefits For the company  Higher Overall Equipment Effectiveness  Less ³firefighting´ to repair machines  Lower operating costs  Better able to meet commitments to customers  Improved ability to compete in the world marketplace 34 Page. 34 .

production. Review of TPM¶s benefits For employees  Less pressure on maintenance for urgent repairs  Less pressure on production to recover from breakdown losses  Better cooperation between maintenance.Partners for Creative Solutions. Inc. 35 . and other departments  Reduced chance of accidents  Higher job satisfaction  Improved job security 35 Page.

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