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TPM [ Total Productive Maintenance]

Tool for effective and seamless

TPM implementation

1

www.effortsconsulting.com 2

Learning Objective

Understand the concept and philosophy of TPM

Learn the 8 pillars of TPM activities and step-by-step

implementation approach

Learn the TPM tools and be able to identify and eliminate loss

Learn how to kick-start TPM deployment with Autonomous

Maintenance, Planned Maintenance, Focused Improvement,

and Education & Training activities to improve equipment

effectiveness

Understand the roles of a TPM implementation organization

and the critical success factors


Outline

1. Overview of TPM

2. TPM Foundation: 5S & Visual Management

3. Key Tools For TPM

4. Equipment Loss Analysis & OEE

5. The Eight Pillars of TPM

6. TPM Implementation


What is TPM?

Total Productive Maintenance (TPM) is a method

To achieve maximum equipment effectiveness

Through employee involvement

Overview of TPM


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

Overview of TPM


TPM is a Paradigm shift

Overview of TPM


Why is TPM Important?

1. It guarantees dramatic results (Significant

tangible results)

• Reduce equipment breakdowns

• Minimize idle time and minor stops

• Less quality defects and claims

• Increase productivity

• Reduce manpower and cost

• Lower inventory

• Reduce accidents

Overview of TPM


Cont..

2. Visibly transform the workplace (plant

environment)

• Through TPM, a filthy, rusty plant covered in oil and

grease, leaking fluids and spilt powders can be

reborn as a pleasant and safe working environment

• Customers and other visitors are impressed by the

change

• Confidence on plant’s product increases

Overview of TPM


Cont..

3. Raises the level of workers knowledge and

skills

As TPM activities begin to yield above

concrete results, it helps:

• The workers to become motivated

• Involvement increases

• Improvement suggestions proliferate

• People begin to think of TPM as part of the job

Overview of TPM


TPM Goal

• Maximize equipment

effectiveness

• Zero breakdowns

• Zero Defect

• Zero Accidents

Overview of TPM

Zero Waste !


Eight Pillars of TPM

Overview of TPM


Tangible and Intangible Benefits of TPM

Tangible benefits:

Productivity up due to

Sudden breakdowns down

Overall facilities effectiveness up

Process defect rate down

Customer compliant/claims down

Products and work-in-process down

Shutdown accidents down

Pollution incidents down

Improvement suggestions up

Overview of TPM


Tangible benefits (contd.):

Financial losses drop due to reduction in breakdowns

Repair costs drop

Maintenance labour-hours reduce

Energy costs reduce

Company’s manufacturing profit ratio up

Overview of TPM


Intangible benefits

Achieving full-self management

• Operators have ownership of their equipments

• They look after it by themselves without direction

Eliminating breakdowns and defects

Growing confidence and ‘can-do’ attitude

Making previously dirty and oily workplaces to a

unrecognizably clean, bright and lively

Giving better image to the visitors and thereby getting

more orders

Overview of TPM


Sort: Identifying Red-tag Target

TPM Foundation


Visual Control – TPM Scorecard

TPM Foundation


Example – Visual Control

TPM Foundation


TPM Tools

• Small group activities

• Suggestion system

• Fuguai tagging

• One point lessons

• Activity board

Key TPM Tools


Fuguai Tagging

• Fuguai Tags are attached to

equipment where problems are

discovered

• 2 categories of Fuguai Tags:

• Blue Tag – repairs by operator

• Red Tag – repairs by

maintenance staff

• Fuguai Register

• A log for all Fuguai’s issued

and resolved

TPM Foundation


3 Purposes of One-Point Lesson

1. To help sharpen equipment-related

knowledge and skills and communicate

information about specific problems and

improvement

2. To share important information easily when it

is needed

3. To improve the performance of the entire

team

Key TPM Tools


Types of One-Point Lessons

Key TPM Tools


Activity board

Key TPM Tools


Six Big Equipment Losses

Equipment Loss Analysis & OEE


Visualizing OEE & the Six Big Losses



Equipment Losses & OEE



Improvement Goals For the 6 Big Losses



Goal of Autonomous

Maintenance

Autonomous Maintenance

Prevent

Equipment

Deterioration

Equipment

Restoration

Proper

Management

Establish Basic

Condition

Goal of

Autonomous

Maintenance


7 Steps of Autonomous Maintenance

1. Clean and inspect

2. Eliminate problem sources and inaccessible areas

3. Draw up cleaning and lubricating standards

4. Conduct general inspections

5. Conduct autonomous inspections

6. Standardize through visual workplace management

7. Implement autonomous equipment management



Example: General Inspection



Example: Use of Match Marks


Match marks are placed

on bolts and nuts so that

operator can easily detect

if bolts have been loosen

due to excessive

vibrations. These are

being placed on critical

bolts after each bolt had

received their correct

torque.


Example: Checklist for autonomous inspection



Example: AM – Who does what?



Example: Colour –coded lubrication container station



What is Preventive Maintenance?

• Daily maintenance to prevent

deterioration

• Inspections to measure

deterioration

• Regular operating checkups

• Early treatment to correct the

defects of deterioration

• Planned Maintenance

Planned Maintenance


The Four Key TPM Pillars that are Critical for Equipment Reliability

Planned Maintenance


Example of TPM implementation structure

TPM implementation


12 Steps of TPM Implementation

TPM implementation


How to Sustain TPM

• Engaging employees

• Aim for early success

• Providing active leadership

• Share success stories

• Rewards and recognition

• Continuously improve OEE

• Evolving the TPM initiative

over time and integration with

Lean

Sustaining TPM

Effort Consulting

Get in touch with us

Efforts Consulting Pvt. Ltd.

508, Palladium Business Centre,

Opp. 4D Square Mall,

Near IIT Engg. College,

Gandhinagar Road, Ahmadabad – 382424

(+91) 9879391004

www.effortsconsulting.com

TRAINING / COACHING / CONSULTING

@ EFFORT CONSULTING 39

Our services

• Business Transformation

• Enterprise Management System

• Strategy & Digital Marketing

• IRMM (Digital Factories)

• Lean Six Sigma

• Time and Motion Study

• MFCA

• Productivity Norms

http://www.effortsconsulting.com/

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