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T otal P roductive M aintenance and FTM From Werardt. A presentation by Werardt Systemss P Ltd. Why TPM?. Increases Productivity Labor productivity, and Break down reduction Improves Quality by Reducing the Defects in processes Reducing Defects in products Reducing Customer complaints.

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T otal p roductive m aintenance and ftm from werardt l.jpg

Total Productive MaintenanceandFTM From Werardt

A presentation by Werardt Systemss P Ltd


Why tpm l.jpg
Why TPM?

Increases Productivity

  • Labor productivity, and

  • Break down reduction

    Improves Quality by

  • Reducing the Defects in processes

  • Reducing Defects in products

  • Reducing Customer complaints


Why tpm3 l.jpg
Why TPM?

Reduces Cost

  • Reduction in man power

  • Maintenance cost reduction

  • Energy Conservation

    Delivery

  • Stock reduction

  • Inventory turnover increase

    Safety Environment

  • Improvement Ideas increase

  • Small Group meetings increase


Why tpm4 l.jpg
Why TPM?

Financial

  • Return on Investment (ROI) after 2 to 3 years

  • Break even on initial TPM project – Less than one year

  • Reduction in absenteeism, as work place is enriched


Tpm goals l.jpg
TPM Goals

  • Zero unplanned Downtime

  • Zero Defects

  • Zero failure

  • Zero variability

  • Reduced Idle time on machines

  • Zero Accidents

  • Maximized P.M. Compliance

  • Thus Maximizing OEE

FTM puts you on the road to achieve these Goals in a Simple, Better and Faster way !


The pillars of tpm l.jpg
The Pillars of TPM

1 Kobetsu Kaizen - Individual Improvements

2 Jishu-Hozen - Autonomous Maintenance

3 Planned Maintenance

4 Quality Maintenance

5 Education and Training

6 Safety and Environment

7 Office TPM

8 Development Management

TPM is a cultural change and FTM supplements it in Information management


Some facts about tpm maintenance l.jpg
Some “Facts” about TPM & Maintenance

  • Maintenance can generally account for a major portion of today’s manufacturing costs

  • Hence when it comes to TPM implementation the Maintenance department generally takes the lead

  • Generally upto 25% of maintenance cost is wasted or not known

  • Emergency repair jobs are at least three times more expensive than the same repair done a pre-planned basis.

Hence TPM & Maintenance go hand-in-hand


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How to achieve Zero Breakdowns?

  • RCFA - Root Cause Failure Analysis

  • Making P.M. effective and dynamic

  • Condition & Time Based Maintenance

  • Doing Why-Why Analysis and maintaining 6W2H

  • Improving the Reliability of work

  • Reducing Idle time on repairs

  • Condition Monitoring and Inspection

  • Autonomous Maintenance activities

FTM is very strong in this area !


The ftm steps to success l.jpg
The FTM Steps to Success

  • Awareness : Understanding your activities, Identifying Critical, Essential and Desirable requirements

  • Business Process Optimization : What processes do you follow to achieve your objectives? Who is doing what? Are they trained for the Job? Are required skills available?

  • Quantification : How many and which type of Jobs do you do? To focus on the type of work being done, how much is reactive and how much is proactive?

  • Benchmarking : FTM helps in devising and defining your Key measuring parameters or KPI’s that help in Improvements

  • Performance Review : And most importantly devising a post implementation review mechanism to monitor progress


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Maintenance Prevention Design

  • Facilitating autonomous maintenance or Jishu Hozen, through Activity based PM, and feedback on machine behavior

  • Applying Kaizen activities to monitor Improvements

  • Increasing the ease of operation, make it easy from information and work point of view

  • Improving skills through need based training programs and easy availability of history

  • Improving maintainability through condition monitoring and reliable operations

  • Improving safety through awareness

Applying FTM feedback !


Key result areas l.jpg
Key Result Areas

1. Improving human resources

  • Operators’ ability to perform Jishu-Hozen

  • Maintenance employees’ ability to perform quality & reliable maintenance

  • Production engineers’ ability to execute maintenance free equipment plan

    2. Improving Plant & Machinery

  • Maximizing Uptime

  • Increased Plant value

  • Achieving TPR - Total Plant Reliability


Key result areas12 l.jpg
Key Result Areas

3. Improving the corporate culture

  • From authoritarian to participative management

  • Involving everyone in CIP

    4. Reducing losses

  • Down time losses

  • Speed losses

  • Defect losses

FTM directly and indirectly helps you in achieving the above


Contact information l.jpg
Contact Information

Werardt Systemss Pvt Ltd

Pune, India

Phone : 91-20-25285256, 25285257

Website : http://www.werardt.com

email: [email protected]


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