a nation grows with improved productivity

8/14/2019 A Nation Grows With Improved Productivity

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A Nation Grows with Improved ProductivityA Nation Grows with Imp

roved Productivity

Why dont you

take care of me?

Im badly sick...

Dont kill me!

Ill do something

for you.

The definite

solution isTPM.TTotalotal

PProductiveroductiveMMaintenanceaintenance

is foris forEveryoneEveryone


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Four Development Stages of Maintenance in Japan

MODEL

BREAKDOWN MAINTENANCE

PREVENTIVE MAINTENANCE

- establishing maintenance functions

PRODUCTIVE MAINTENANCE

- recognizing importance of reliability, maintenance, and

economic efficiency of plant design

TOTAL PRODUCTIVE MAINTENANCE

- achieving PM efficiency through a comprehensive system

based on respect for individuals and total employeeparticipation

PREDICTIVE AND DIAGNOSTIC MAINTENANCE

- adopting modern monitoring and analyzing techniques to

diagnose the condition of equipment during operation

- to identify the sign of deterioration or immense failure

PERIOD

~ 1950

1950 ~ 1960

1960 ~ 1970

1970 ~

1985 ~

STAGE

1

2

3

4

4+


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What is Total Productive Maintenance?

Total Productive Maintenance (TPM)

combines the American practice of

preventive maintenance with the Japanese

Total Quality Control and total employeeinvolvement. The result is an innovative

system for equipment maintenance that

optimizes effectiveness, eliminatesbreakdowns, and promotes autonomous

operator maintenance through day-to-day

activities.


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The Five Pillars of TPM

2

1

3

4

5

TPM aims to maximize equipment overall

effectiveness.

TPM establishes a thorough system of PM for theequipment entire life span.

TPM is implemented by various departments -engineering, operations, and maintenance.

TPM involves every single employee, from topmanagement to workers on the floor.

TPM is based on the promotion of PM throughmotivation management: autonomous small groupactivities.


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Principal Features of TPM

The word total in total productive maintenance has

three meanings that describe the principal features ofTPM:

2

1

3

Total effectiveness (referred to in point 1 above)indicates TPM's pursuit of economic efficiency or

profitability.

Total maintenance system (point 2) includesmaintenance prevention (MP) and corrective

maintenance (CM) as well as preventivemaintenance (PM).

Total participation of all employees (point 3,4 and5) includes autonomous maintenance by

operators through small group activities.


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The Six Big Equipment Losses and Overall Equipment Effectiveness

Equipment Six big losses Calculation of overall equipment effectiveness

Loading time

Operating time

Do

wntime

losses

Net

operating

timeSpeedlosses

Valuable

operating

timeDefectlosse

s

1Equipment failure

2

Setup and adjustment

3

Idling andminor stoppages

4

Reduced speed

5

Defects in process

6

Reduced yield

Overall equipment effectiveness = Availability x Performance efficiency x Rate of quality products

(e.g.) 0.87 x 0.50 x 0.98 x 100 = 42.6%

Performance efficiency = x 100

(e.g.)

Performance efficiency = x 100 = 50%0.5 mins / unit x 400 units

400 mins

theoretical cycle time x processed amountoperating time

Availability = x 100

(e.g.)

Availability = x 100 = 87%

loading time - downtime

loading time

400 mins - 60 mins

460 mins

processed amount - defect amount

processed amountRate of quality products = x 100

(e.g.)

Rate of quality products = x 100 = 98%400 units - 8 units

400 units


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Accurate Data is Essential

If we want to practice profitable TPM and pursueoptimal equipment effectiveness, the following twofactors are crucial. First, we must keep accurateequipment operation records so that the appropriatemanagement and controls can be provided; and second,we must devise a precise scale for measuring the

equipment operation conditions.

Equipment operation conditions are not reflectedaccurately when they are based solely on the availability(operation time ratio) figure. Of the six big equipmentlosses, only downtime losses are calculated to determineavailability. Other equipment losses such as speed anddefect losses are not accounted for. To represent actualequipment operating conditions accurately, all six

equipment losses must be included in the calculations.


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Calculations of Overall Equipment Effectiveness

A:

B:

C:

D:

E:

G:H:

I:

J:

F:T:

M:

N:

L:

Running time per day = 60 minutes x 8 hours = 480 minutes

Downtime per day (downtime accounted for in the production schedule for

scheduled maintenance, or for management purposes such as morning

meetings) = 20 minutes

Loading time per day = A - B = 460 minutes

Stoppage losses per day (breakdowns - 20 minutes; setup - 20 minutes;

adjustment - 20 minutes) = 60 minutes

Operating time per day = C - D = 400 minutes

Output per day = 400 unitsRate of quality products: 98%

Ideal cycle time = 0.5 minutes / unit

Actual cycle time = 0.8 minutes / unit

Therefore,

Actual processing time = J x G = 0.8 x 400 = 320 minutesAvailability = E / C x 100 = 400 / 460 x 100 = 87%

Operating speed rate = I / J x 100 = 0.5 / 0.8 x 100 = 62.5%

Net operating rate = F / E x 100 = (0.8 x 400) / 400 x 100 = 80%

Performance efficiency = M x N x 100 = 0.625 x 0.800 x 100 = 50%

Overall Equipment effectiveness = T x L x H x 100 = 0.87 x 0.50 x 0.98 x 100= 42.6%


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What is the Ideal Overall Equipment Effectiveness?

The ideal conditions are:

Availability: greater than 90%

Performance efficiency: greater than 95%

Rate of quality products: 99%

Therefore, the ideal overall equipment effectiveness

should be:

0.90 x 0.95 x 0.99 x 100 = 85+%

This figure is not just a remote goal. All the PM prize

winning companies in Japan have an equipment

effectiveness greater than 85 percent.


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Calculations Chart for Overall Equipment Effectiveness

Calculations Chart for Overall Equipment Effectiveness

A B C D E F T G H I J L M N

Quantity process ed

Running Planned Loading Downtime Operating Actual Operating Output Total Quali ty Standard Actual Operation Operation Net Number Number of Overal l

t ime downtime time loss time processing time (number of ( including losses ratio cycle cycle performance speed operation of minor exchanges equipment

time ratio quality produc ts ) and rewo rk) time time ratio r atio ratio s toppages of diamond ef fec tiveness

Process grindstones

(h) (h) (h) (h) (h) (h) (%) (unit) (unit) (%) (s) ( s) (%) (%) (%) (%)

A-B C-D JxG E/C G1 G G1/G MxN I/J F/E TxLxH

Internal 17.75 2.30 15.45 0.00 15.45 10.94 100.00 4,000 4,018 99.55 9.50 9.80 68.63 96.94 70.80 2 2 68.32

finish 18.58 0.60 17.98 0.00 17.98 13.12 100.00 4,800 4,818 99.63 9.50 9.80 70.71 96.94 72.95 4 2 70.45

16.83 0.70 16.13 0.00 16.13 12.03 100.00 4,400 4,418 99.59 9.50 9.80 72.28 96.94 74.56 0 2 71.98

Total 53.16 3.60 49.56 0.00 49.56 36.08 100.00 13,200 13,254 99.59 9.50 9.80 70.57 96.94 72.80 6 6 70.29

6.50 0.10 6.40 0.50 6.40 4.62 100.00 1,187 1,190 99.75 14.00 16.60 60.88 84.34 72.19 1 3 60.73

External 17.75 0.70 17.05 0.00 17.05 16.38 100.00 3,513 3,542 99.18 14.00 16.65 80.79 84.08 96.08 0 8 80.13

finish 17.75 0.80 16.95 0.00 16.95 15.12 100.00 3,297 3,309 99.64 14.00 16.45 75.92 85.11 89.21 0 6 75.64

16.00 1.10 14.90 0.00 14.90 14.13 100.00 3,030 3,150 96.19 14.00 16.15 82.21 86.69 94.84 0 6 79.08

Total 58.00 2.70 55.30 0.50 55.30 50.25 100.00 11,027 11,191 98.53 14.00 16.46 77.28 85.04 90.87 1 23 76.15

6.50 0.10 6.40 0.20 6.20 3.47 96.88 1,187 1,202 98.75 9.50 10.40 51.16 91.35 56.01 0 1 48.94

External 17.75 0.70 17.05 0.00 17.05 10.48 100.00 3,513 3,593 97.77 9.50 10.50 55.61 90.48 61.46 0 4 54.37

finish 17.75 0.80 16.95 0.00 16.95 9.89 100.00 3,297 3,392 97.20 9.50 10.50 52.81 90.48 58.37 0 3 51.33

16.00 1.10 14.90 0.00 14.90 8.84 100.00 3,030 3,060 99.02 9.50 10.40 54.19 91.35 59.33 0 3 53.66

Total 58.00 2.70 55.30 0.20 55.30 32.69 100.00 11,027 11,247 98.04 9.50 10.45 53.73 90.91 59.11 0 11 52.68


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The Twelve Steps of TPM Development

1

2

3

4

5

6

7

8

9

10

11

12

Announce top managements decision to introduce TPM

Launch education and campaign to introduce TPM

Create organization to promote TPM

Establish basic TPM policies and goals

Formulate master plan for TPM development

Hold TPM kick-off

Improve effectiveness of each piece of equipment

Develop an autonomous maintenance program

Develop a scheduled maintenance program for the maintenance department

Conduct training to improve operation and maintenance skills

Develop initial equipment management program

Perfect TPM implementation and raise TPM levels


13/13

A Nation Grows with Improved ProductivityA Nation Grows with Improved Productivity

TPMTPMisisfor Everyonefor Everyone

End of PresentationEnd of Presentation

Thank you

foryour patience

a nation grows with improved productivity

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