Total Productive Maintenance

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Total Productive Maintenance: 

Total Productive Maintenance

TPM Training Agenda: 

2 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: 

3 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 TPM: 

4 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 : 

5 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: 

6 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: 

7 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: 

8 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: 

9 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: 

10 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: 

11 Shift in Attitudes Operator Maintenance Operator Maintenance Conventional TPM I use I maintain & I fix We maintain

5 Pillars of TPM: 

12 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: 

13 TPM Emphasizes Prevention Three Principles of Prevention Maintain normal conditions Early discovery of abnormalities Operator Maintenance Prompt response

The Six Big Equipment Losses: 

14 The Six Big Equipment Losses Breakdowns Setups and adjustment Idling and minor stoppages Speed Quality defects and rework Start-up (loss of yield)

PowerPoint Presentation: 

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

PowerPoint Presentation: 

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: 

17 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: 

18 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 Breakdowns: 

19 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 Breakdowns: 

20 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: 

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 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: 

22 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 Maintenance: 

23 Steps to Implementing Autonomous Maintenance Step 6: Organize and manage the workplace Step 7: Ongoing autonomous maintenance and continued improvement

An advanced Improvement method: 

24 An advanced Improvement method Maintenance Prevention Design-stage activities aimed at making new equipment reliable, easy to care for, and user friendly

TPM Standards Enhance Success: 

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

Sustaining TPM: 

26 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: 

27 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: 

28 Setting Up a TPM Structure EIT EIT EIT EIT EIT EIT TPM Advisory Team Mgmt

Advisory Team - Responsibilities: 

29 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: 

30 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: 

31 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: 

32 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: 

33 Shift in Equipment Maintenance Activities Breakdown PM Planned repair FROM THIS to Autonomous PM Predictive Planned repair Breakdown THIS

Review of TPM’s benefits: 

34 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 benefits: 

35 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