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Total Productive Maintenance and Maintenance Management http://www.managementsupport.com Outline What is Total Productive Maintenance Origins of TPM TPM Principles Components of TPM Autonomous Maintenance Planned Maintenance Equipment & Process Improvement

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total productive maintenance and maintenance management http www managementsupport com

Total Productive Maintenanceand Maintenance Managementhttp://www.managementsupport.com

outline
Outline
  • What is Total Productive Maintenance
  • Origins of TPM
  • TPM Principles
  • Components of TPM
    • Autonomous Maintenance
    • Planned Maintenance
    • Equipment & Process Improvement
    • Early Management of New Equipment
    • Process Quality Management
    • TPM in the Office
  • Implementing TPM
  • TPM Benefits
  • Maintenance Management & Strategy
what is tpm
What is TPM
  • A company-wide team-based effort to build quality into equipment and to improve overall equipment effectiveness
  • Total
    • all employees are involved
    • it aims to eliminate all accidents, defects and breakdowns
  • Productive
    • actions are performed while production goes on
    • troubles for production are minimized
  • Maintenance
    • keep in good condition
    • repair, clean, lubricate
autonomous maintenance
Autonomous Maintenance
  • 7 steps are implemented to progressively increase operators knowledge, participation and responsibility for their equipment
    • 1. Perform initial cleaning and inspection
    • 2. Countermeasures for the causes and effects of dirt and dust
    • 3. Establish cleaning and lubrication standards
    • 4. Conduct general inspection training
    • 5. Carry out equipment inspection checks
    • 6. Workplace management and control
    • 7. Continuous improvement
early management of new equipment
Early Management of New Equipment
  • Objective: establish systems to shorten
    • new product or equipment development
    • start-up, commissioning and stabilization time for quality and efficiency
  • New equipment needs to be:
    • easy to operate
    • easy to clean
    • easy to maintain and reliable
    • have quick set-up times
    • operate at the lowest life cycle cost
7 develop equipment management program
7: Develop Equipment Management Program
  • The tools of Total Quality Management and Continuous Improvement are applied to the management and improvement of equipment
  • Form project teams
  • Select model equipment
    • identify equipment problems
    • analyze equipment problems
    • develop solutions and proposals for improvement
the strategic importance of maintenance and reliability
The Strategic Importance of Maintenance and Reliability
  • Failure has far reaching effects on a firm’s
    • operation
    • reputation
    • profitability
    • customers
    • product
    • employees
    • profits
tactics for reliability and maintenance
Tactics for Reliability and Maintenance
  • Reliability Tactics
    • improving individual components
    • providing redundancy
  • Maintenance Tactics
    • implementing preventive maintenance
    • increasing repair capabilities
organizing the maintenance function
Organizing the Maintenance Function
  • Centralized maintenance department
    • Does all maintenance (PM & breakdown)
  • Decentralized maintenance department
    • Useful if different equipment used in different areas of company
  • Contract maintenance
    • Used if little equipment or expertise
  • Operator ownership approach
increasing repair capabilities features of a good maintenance facility
Increasing Repair Capabilities:Features of A Good Maintenance Facility
  • Well-trained personnel
  • Adequate resources
  • Ability to establish a repair plan and priorities
  • Ability and authority to do material planning
  • Ability to identify the cause of breakdowns
  • Ability to design ways to extend MTBF