Total Productive Maintenance (TPM) by Allan Ung


Presentation Description

Training presentation on Total Productive Maintenance (TPM). Includes the concept and management philosophy of TPM, the 8 pillars of TPM activities, TPM implementation strategy, and step-by-step implementation approach. To download this complete presentation, please go to:


Presentation Transcript

Slide 1:

Total Productive Maintenance (TPM): Maximizing Equipment Effectiveness for Operational Excellence Allan Ung Managing Consultant Operational Excellence Consulting

Learning Objectives :

Learning Objectives Understand the concept and philosophy of  TPM as a foundation for Lean Transformation Learn the 8 pillars of TPM activities, TPM implementation strategy, roadmap and step-by-step approach Learn the TPM tools and be able to identify and eliminate loss through TPM implementation Understand the Autonomous Maintenance process and how to improve equipment reliability Understand the roles of a TPM implementation organization and the critical success factors Copyrights of all the pictures used in this presentation are held by their respective owners.

Program Outline:

Program Outline Overview of TPM TPM Foundations: 5S & Visual Management TPM Tools Equipment Loss & OEE 8 Pillars of TPM Autonomous Maintenance Planned Maintenance Integration of Autonomous Maintenance & Planned Maintenance TPM Implementation Critical Success Factors NOTE: As this is a PREVIEW , only selected slides are shown. To download the complete presentation, please visit:

Overview of TPM:

Overview of TPM

TPM Definition:

TPM Definition Total Participation of all employees and all departments Covers all operations, equipment and process Productive Pursue the maximization of production efficiency by elimination of all losses and waste Zero accidents, zero defects and zero breakdowns Maintenance Proactive and preventive maintenance to maximize operational efficiency of equipment Effective collaboration between production and maintenance Empowerment of operators to help maintain their equipment

TPM Principles:

TPM Principles Increase Overall Equipment Effectiveness (OEE) Improve existing planned maintenance systems The operator is the best condition monitor Provide training to upgrade operations and maintenance skills Involve everyone and utilize cross-functional teamwork

Characteristics of TPM:

Characteristics of TPM Optimum relationships between people and equipment/process Involvement of everyone, from top leadership to shop-floor workers A cross-functional approach, involving all departments Implementation through small group activities A fact-based approach to continuous improvement

TPM is a Paradigm Shift:

TPM is a Paradigm Shift Maintenance Operator Maintenance Old Attitude TPM Attitude I use I maintain & I fix We maintain Operator

Why TPM?:

Why TPM? Avoid wastage in a quickly changing economic environment Producing goods without reducing product quality Produce a low batch quantity at the earliest possible time Reduce cost Goods delivered to customers must be non-defective

TPM Goals:

TPM Goals Zero unplanned downtime Zero speed losses Zero defects Zero accidents Minimum life cycle cost Zero waste!

Eight Major Pillars of TPM:

Eight Major Pillars of TPM TPM in the Office Safety & Environmental Management Autonomous Maintenance Planned Maintenance Focused Improvement Early Equipment Management Quality Maintenance Education & Training 5S & Visual Management TPM Goals: Zero Defects, Zero Breakdowns, Zero Accidents

TPM Foundations: 5S & Visual Management:

TPM Foundations: 5S & Visual Management

What is 5S?:

What is 5S? 5S is a structured program to implement workplace organization and standardization 5S represents five disciplines for maintaining a visual workplace 5S is a foundation to Kaizen and Lean implementation, e.g. TPM 5S

What Do 5S & TPM Have in Common?:

What Do 5S & TPM Have in Common? Cleaning and restoring condition Monitoring and inspecting Lubricating and repairing Improving and organizing Training Measuring

TPM Tools:

TPM Tools

TPM Tools:

TPM Tools Small group activities Suggestion system Fuguai tagging One point lessons Activity board

Small Group Activities – Problem-solving Process:

Small Group Activities – Problem-solving Process Define the Problem Collect Data Identify Possible Casual Factors Identify the Root Cause(s) Implement Countermeasures

Fuguai Tagging:

Fuguai Tagging Fuguai Tags are attached to equipment where problems are discovered Two categories of Fuguai Tags: Blue Tag – repairs can be made by operator Red Tag – repairs by maintenance staff Fuguai Register A log for all Fuguai’s issued and resolved

Equipment Loss & OEE:

Equipment Loss & OEE

Loss Structure in Production Activities:

Loss Structure in Production Activities Operating worker-hours Operating hours Loading worker-hours Loading hours Actual working worker-hours Utilization hours Effective working worker-hours Net utilization hours Value-added worker-hours Value-added hours Human Equipment Management Losses Motion Losses Line Organization Losses Losses resulting from failure to automate Measuring and adjustment losses Shut Down Losses Breakdown Losses Setup and Adjustment Losses Start-Up Losses The losses which decrease the human work efficiency The losses which decrease the equipment efficiency Other Stoppage Losses Reduced Speed Losses Typical Equipment Losses Defect/Rework Losses Minor stoppage/Idling Losses Six Major Losses Energy Losses Logistics Losses

Overall Equipment Effectiveness (OEE) 1:

Overall Equipment Effectiveness (OEE) 1 Waste Planned Production Time Operating Time Downtime Loss Net Operating Time Speed Loss Fully Productive Time Quality Loss Planned Shutdown Plant Operating Time

Strategies for Zero Breakdowns:

Strategies for Zero Breakdowns Restore equipment Maintain basic equipment conditions Adhere to standard operating procedures Improve operator maintenance skills Don’t stop at quick fixes Correct design weaknesses Study breakdowns relentlessly

Improving Equipment Reliability through Integration of AM & PM:

Improving Equipment Reliability through Integration of AM & PM

Integration of Autonomous Maintenance with Planned Maintenance & Education & Training:

Integration of Autonomous Maintenance with Planned Maintenance & Education & Training Training plays an important part in the transfer of basic knowledge and skills from Maintenance to Operations

Goals of Autonomous Maintenance:

Goals of Autonomous Maintenance

Example of Autonomous Maintenance:

Example of Autonomous Maintenance Source: Nippon Denso

Slide 27:

Preventive Maintenance Corrective Maintenance Maintenance Prevention Breakdown Maintenance Support for Autonomous Maintenance Specialized maintenance skills Equipment repair skills Inspection and measurement skills Equipment diagnostic skills Develop new maintenance technologies

Implementing Autonomous Maintenance With Planned Maintenance:

1 – Initial c leaning 2 – Sources of contamination, Hard-to- reach area 3 – Standardize 4 – Inspection system 5 – Entire process inspection 6 – A.M. System 7 – A.M. Management INCREASE TIMELIFE IMPROVE MTBF SYSTEMATIC REPAIR FAILURE PREDICTION PHASE 1 PHASE 2 PHASE 3 PHASE 4 1 – Equipement Audit ( Current ) 2 – Repair degradations and improve weakness 3 – Information system ( Database ) 4 – Preventive Maintenance System 5 - Predictive Maintenance System AUTONOMOUS MAINTENANCE PLANNED MAINTENANCE 6 - Evaluate & Establish PLANNED MAINTENANCE SYSTEM Implementing Autonomous Maintenance With Planned Maintenance

TPM Implementation:

TPM Implementation

12 Steps of TPM Implementation (Nakajima):

12 Steps of TPM Implementation (Nakajima) Preparation Kick-off Implementation Announcement to introduce TPM Introductory education campaign for the workforce TPM Promotion (special committees) Establish basic TPM policies and goals Preparation and Formulation of a master plan Develop an equipment management program Develop a planned maintenance program Develop an autonomous maintenance program Increase skills of production and maintenance personnel Perfect TPM implementation and raise TPM levels Stabilization Develop early equipment management program Invite customers, affiliated companies and subcontractors

End of Preview:

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