Download - 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
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A Nation Grows with Improved ProductivityA Nation Grows with Improved Productivity
TPMTPMisisfor Everyonefor Everyone
End of PresentationEnd of Presentation
Thank you
foryour patience