TPM

TOTAL
PRODUCTIVE
MAINTENANCE
 TPM: Six Major Losses
 Downtime Losses:
 1. Equipment failures or breakdowns.
 2. Delayed setups and increased adjustments.
 Speed losses
 3. Jams, work-piece caught on an obstruction or component.
 Sensors trips and shuts machine down due to overloads,
 quality problems (mistake proofing).
 4. Reduced speed, optimal speed unknown and higher speeds
 cause problems.
 Defect Losses
 5. Process defects leading to scrap and rework, deteriorating quality.
 6. Reduced yields from machine startup to stabilize production.
How Do They Change the Culture?

 Systems drive Behaviors

 Behaviors drives Culture

 To develop a culture of continuous

improvement you must put systems in
place that give you the repeatable
behaviors you want.
 6S

 Most World Class companies always start

with 6S

 Why?
 TPM:
Begin process with 5-S Program

Sort
Set in Order
Shine
Standardize
Sustain
Safety
 Maintenance
Traditional vs. Lean Manufacturing
 1-Only performed as needed.  1-Continual and effective.

 2-In many cases not done due to  2-Disciplined preventive maintenance

 time or spare equipment/parts. for all critical equipment.
 3-Established scheduled.

 3-Lack of priorities.
 4-Integrated with production on a
 cross functional maintenance team.
 4-Maintenance is not part of the  5-Operators and setup people are cross
 production team trained to perform “routine”
 maintenance.
 5-Operators & setup people not  6-Predictive maintenance
involved and Maintenance done by
“specialists”.  7-This machine is yours. You are
 6-When it is running, let it run.
responsible. “Ownership”
 7-Lack of concern with
 maintenance.
 TPM Objectives
Lower actual maintenance costs
More available production time
Improved quality
Machines hold better tolerances
Lower operator fatigue “fighting the machine”
Better working conditions, less stress
Enable “Just in Time” production
Reduce changeover times
TPM Objectives
Avoid major breakdowns
Reduce costs by:
• Increasing asset life
• Reducing scrap and rework
• Reduce replacement parts costs
• Reduce delays and disruptions
Everyone is involved in the process
Eliminate accidents
Zero unplanned downtime
 Four Stages of TPM
 Corrective (Reactive) maintenance
 Preventive maintenance
 Predictive maintenance
 Total Productive Maintenance

 Corrective Maintenance
+ Preventive Maintenance
+ Predictive Maintenance
= Continuous Improvement In Maintenance
Or: Total Productive Maintenance
 Reactive Maintenance

 “ Fire fighting mode ”

 Interruptions to production at times result in missed
schedules due to machine breakdowns.
 Parts for failed equipment often have to be flown in
from supplier.
 This shows up as reduced utilization of critical
equipment, due to the unplanned down time.
 Reactive Corrective Maintenance
Transition Process

 Issue and close out maintenance work-orders

 Maintain complete maintenance records on
each piece of equipment.
 Analyze failures and determine reason for
failures.
 Track maintenance cost on each piece of
equipment, labor and material.
 Measure reliability of critical equipment.
 Reactive Corrective Maintenance
LEAN Process

 Maintain adequate inventories of spare parts

based on historical data.
 Correct design weakness in equipment based
on failure analysis.
 Begin autonomous maintenance.
 Begin training of operators and maintenance
people in TPM.
Preventive Maintenance includes:

Maintenance Planning
Prioritize departments, start with critical areas
or departments.
Rank equipment as critical or non critical.
Establish through Impact teams preventative
maintenance requirements per day, per week,
per month, per year.
Issue work orders/check off sheets, close out
work orders and check off sheets.
Plan major maintenance projects.
Preventive Maintenance includes:

Maintenance Record archives with detail records

Use for planning and spending decisions
Ask WHY 5 TIMES. (5-WHY’s) to get to “ROOT
CAUSE” (Problem Solving)
Types of records
• Routine Inspection & Lubrication
• Repair, maintainability, improvements
• “Equipment Failure Analysis”, root cause of
machine failure.
Predictive Maintenance
Use of modern measurement and signal
processing techniques to accurately diagnose
the need for periodic maintenance and overhaul
schedules.
Plan for the shut down of critical equipment and
eliminate unplanned breakdowns.
Some Predictive Maintenance Tools

 Oil Analysis
 Vibration Analysis
 Ultrasonic
 Fluid Contamination Analysis
 TPM System
Total Productive Maintenance

Using all the people, not just “Maintenance, to complete

corrective, preventative and predictive maintenance on a
daily basis to prevent unplanned downtime

 Corrective + Preventive + Predictive Maintenance

= Continuous Improvement In Maintenance
 or TPM
Total Productive Maintenance

Seven Steps To Success

Step
7
Step Autonomous Control
6
Step 5 Standardization
S t ep Autonomous Inspection
4
Step General Inspection
3
Step 2 Cleaning, Lube & Inspection Standards

Step Eliminate Sources of Problems

1
Hands-on Initial Cleaning
Machine Leakage Issues

Coolant &
Hydraulic
Fluids on
Exterior

Air &
Lubrication in
Hard-to-reach
location
 Operator Maintenance

Seven Steps To Success

Step
7 Autonomous Control
Step
6 Standardization
Step 5
Autonomous Inspection
S t ep
4 General Inspection
Step
3
Cleaning, Lube & Inspection Standards
Step 2
Eliminate Sources of Problems
Step
1
Hands-on Initial Cleaning
Campbell Machine
 Operator Maintenance
Step 2 – Eliminate Sources
Main Actions Before
 Corrections and improvements
listed up during step #1 Hard
to inspect

Objectives
 Safety and environmental
concerns resolved
 Reducing time required for
cleaning, inspecting and
lubricating
Easy
 Repairing all outstanding to inspect
abnormalities
After
 Operator Maintenance

Seven Steps To Success

Step
7 Autonomous Control
Step
6 Standardization
Step 5
Autonomous Inspection
S t ep
4 General Inspection
Step
3
Cleaning, Lube & Inspection Standards
Step 2
Eliminate Sources of Problems
Step
1
Hands-on Initial Cleaning
 Preventive Maintenance
- Training

Example - Lubrication Training

• Color code bulk lube containers

• Color coded lube points match containers
• Develop standards for handling lubes
• Lube management system consolidating lubricants
• Lube method, quantity, timing
• Detailed instructions for PM
• Chart with a diagram or digital picture
 Operator Maintenance

Seven Steps To Success

Step
7 Autonomous Control
Step
6 Standardization
Step 5
Autonomous Inspection
S t ep
4 General Inspection (Keep Things Like “NEW”
Step
3
Cleaning, Lube & Inspection Standards
Step 2
Eliminate Sources of Problems
Step
1
Hands-on Initial Cleaning
 Campbell Machine

s this good for the EQPT.

IS
it
SAF
E
 Operator Maintenance

Seven Steps To Success

Step
7 Autonomous Control
Step
6 Standardization
Step 5
Autonomous Inspection
S t ep
4 General Inspection
Step
3
Cleaning, Lube & Inspection Standards
Step 2
Eliminate Sources of Problems
Step
1
Hands-on Initial Cleaning
 Autonomous Inspection

 Put a system in place and

teach each “Production
Operator” to check their own
equipment for abnormalities
Operator Maintenance

BEFORE AFTER