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Total Productive Maintenance. TPM Training Agenda. TPM – History, benefits and typical results Definition and “5 Pillars” of TPM The “6 Big Losses” Autonomous Maintenance Maintenance Prevention Setting Standards & Sustaining the Benefits TPM and Safety The Advisory Team

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tpm training agenda
TPM Training Agenda
  • TPM – History, benefits and typical results
  • Definition and “5 Pillars” of TPM
  • The “6 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
origins of tpm
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
origins of tpm4
Origins of TPM
  • Total Productive Maintenance
    • Brought operators into the picture
    • Small group activities
    • Teamwork between operators and maintenance
    • Involvement & support throughout the company
no tolerance for breakdowns
No Tolerance for Breakdowns
  • Equipment breakdowns impact
    • Customer service
    • Production costs
    • Maintenance costs
    • Effectiveness of “manufacturing cells” or “flow lines”
  • Breakdowns result in “chaos”
the last 50 years
The Last 50 Years
  • In the 1950’s, about 70% of durable goods sold in the world were made in the U.S. …today << 10%
  • In the 1950’s, there were over 25 U.S. television manufacturers …by the early 1990’s, only 1 (Zenith) …today??
  • In the 1950’s, the largest growing job was in manufacturing…not the case today!!

Most manufacturing industries are fighting a war to survive!

benefits of tpm to the company
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

benefits of tpm for operators maintenance personnel
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
typical tpm results
Typical TPM Results
  • Overall equipment effectiveness up 25-65%
  • Quality defects down 25-50%
  • Maintenance expenditures down 10-50%
  • Percent planned vs. unplanned maintenance increased 10-60%
definition
Definition

TPM is a company-wide system developed to maintain, monitor, and improve all capital assets of a company. For production it is a system that maximizes equipment effectiveness and maintains product flow.

  • TPM is not just about “maintenance”. It is about getting the most overall benefit from your equipment over the life of the equipment.
  • TPM will not be an overnight success. Implementing it throughout a plant correctly will take several years.
shift in attitudes
Shift in Attitudes

Maintenance

Operator

Maintenance

Operator

I maintain &

I fix

I use

We maintain

Conventional

TPM

5 pillars of tpm
5 Pillars of TPM
  • 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
tpm emphasizes prevention
TPM Emphasizes Prevention

Three Principles of Prevention

  • Maintain normal conditions
  • Early discovery of abnormalities
    • Operator
    • Maintenance
  • Prompt response
the six big equipment losses
The Six Big Equipment Losses
  • Breakdowns
  • Setups and adjustment
  • Idling and minor stoppages
  • Speed
  • Quality defects and rework
  • Start-up (loss of yield)
slide15

Overall equipment effectiveness = Availability x Performance rate x Quality rate

(OEE)

Breakdown

Setup and adjustment

Others

Quality defects & rework

Start-up yield

Idling & minor stoppages

Reduced speed

slide16

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

improving oee
Improving OEE
  • 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
eliminating breakdowns
Eliminating Breakdowns

Workplace Conditions Contribute to Losses

  • Filthy equipment
  • Oil and lubricant leaks
  • Moving parts encrusted with raw materials or debris
  • Disorderly wiring, hoses, etc.
  • Equipment mechanisms hidden or difficult to access
  • Workplace disorder
  • A belief that conditions cannot improve
eliminating breakdowns19
Eliminating Breakdowns

Why machines fail

  • Disregard for basic needs (housekeeping, lube..)
  • Incorrect operating conditions
  • Lack of skill or knowledge of operator
  • Machine deterioration
    • Routine
    • Accelerated
  • Design deficiency
eliminating breakdowns20
Eliminating Breakdowns
  • Two kinds of breakdowns
    • Function loss (function completely lost) - Sporadic
    • Function reduction (works, but with loss of speed or quality) - Chronic
  • Two kinds of breakdown maintenance
    • Planned (pre-emptive)
    • Unplanned (firefighting)
autonomous maintenance
Autonomous Maintenance

The principal way production workers participate in TPM

Purpose

  • Brings production & maintenance people together to slow routine deterioration and halt accelerated deterioration
  • Helps operators learn more about their equipment (the cause and effect)
  • Prepares operators to be active partners with maintenance and engineering in improving equipment performance and reliability
steps to implementing autonomous maintenance
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, inspection, and lubrication standards

Step 4: General inspection training and inspection procedures

Step 5: Conduct autonomous general inspections

steps to implementing autonomous maintenance23
Steps to Implementing Autonomous Maintenance

Step 6: Organize and manage the workplace

Step 7: Ongoing autonomous maintenance and continued improvement

an advanced improvement method
An advanced Improvement method
  • Maintenance Prevention

Design-stage activities aimed at making new equipment reliable, easy to care for, and user friendly

sustaining tpm
Sustaining TPM
  • Audits
  • Visual activity boards
    • Team charter
    • Team activities, goal, schedule, and progress
    • Cleaning, inspection, and lubrication standards
    • Workplace organization standards
    • Trend charts for each of the big 6 losses
    • Inspection reports
    • Audit results
    • Before and after photos
tpm and safety
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
setting up a tpm structure

EIT

EIT

EIT

EIT

EIT

EIT

Setting Up a TPM Structure

TPM

Advisory

Team

Mgmt

advisory team responsibilities
Advisory Team - Responsibilities
  • Guide & champion TPM implementation
  • Assess current equipment OEE and develop a process for measuring the “6 big” losses
  • Develop a TPM master plan
  • Set plant-wide standards for TPM implementation
  • Monitor and evaluate progress
  • Serve on EIT’s
equipment improvement teams responsibilities
Equipment Improvement Teams - Responsibilities
  • Return equipment to near new condition
  • Investigate and reduce the “big 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
setting goals for your tpm program
Setting Goals for Your TPM Program
  • Short term – 12 months
    • Establish an autonomous maintenance program for “x” machines
    • Increase OEE by “y”% within for individual work centers
  • Long term – Reach a plant OEE of 85% within 3 years (world class is considered about 85%)
comparing tpm to 5s
Comparing TPM to 5S
  • 5S emphasizes
    • Productivity of workers
    • Organizing and visual indicators
  • TPM emphasizes
    • Effectiveness of equipment
    • Partnership between maintenance & production
    • Reducing lifetime equipment costs
  • Both emphasize
    • Initial cleaning and repair
    • Safety
shift in equipment maintenance activities

FROM

THIS

to

Planned repair

PM

Breakdown

Shift in Equipment Maintenance Activities

THIS

Breakdown

Predictive

Planned repair

PM

Autonomous

review of tpm s benefits
Review of TPM’s benefits
  • For the company
    • Higher Overall Equipment Effectiveness
    • Less “firefighting” to repair machines
    • Lower operating costs
    • Better able to meet commitments to customers
    • Improved ability to compete in the world marketplace
review of tpm s benefits34
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, production, and other departments
    • Reduced chance of accidents
    • Higher job satisfaction
    • Improved job security