Total Productive Maintenance (TPM)BYNeeraj Kumar

What is TPMA company-wide team-based effort to build quality into equipment and to improve overall equipment effectivenessTotalall employees are involvedit aims to eliminate all accidents, defects and breakdownsProductiveactions are performed while production goes ontroubles for production are minimizedMaintenancekeep in good conditionrepair, clean, lubricate

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DefinitionTPM 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.Implementing it throughout a plant correctly will take several years.

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No Tolerance for Breakdowns Equipment breakdowns impactCustomer serviceProduction costs Maintenance costs Effectiveness of manufacturing cells or flow linesBreakdowns result in chaos

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Benefits of TPM to the CompanyImproved plant productivity and capacityLower operating costsImproved equipment lifespan Better ability to satisfy customers*Bottom Line: TPM increases long-term benefits

Benefits of TPM for Operators & Maintenance PersonnelIncreased skills through additional trainingBetter job satisfactionOperators More involvement in solving annoying equipment problemsMaintenance More challenging workBetter job security

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Shift in Attitudes*OperatorMaintenanceOperator

Maintenance

ConventionalTPMI useI maintain &I fixWe maintain

5 Pillars of TPMImprovement activities designed to increase equipment effectiveness (OEE)Autonomous maintenance program performed by equipment operatorsA planned maintenance systemTraining to improve operation & maintenance skillsEffective new equipment design and startup*

TPM Emphasizes PreventionThree Principles of PreventionMaintain normal conditionsEarly discovery of abnormalitiesOperatorMaintenancePrompt response*

The Six Big Equipment LossesBreakdowns Setups and adjustment Idling and minor stoppagesSpeedQuality defects and reworkStart-up (loss of yield)

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Six Big Equipment Losses lead to loss ofoperationreputationprofitabilitycustomersproductemployeesprofits

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Overall equipment effectiveness = Availability x Performance rate x Quality rate (OEE)BreakdownSetup and adjustment OthersIdling & minor stoppagesReduced speedQuality defects & reworkStart-up yield

Operation time (Scheduled time available Downtime)Availability = ______________________________________________ x 100

Scheduled time available processed amount x ideal cycle timePerformance rate = _____________________________

Operation time

Eliminating BreakdownsWorkplace Conditions Contribute to LossesFilthy equipmentOil and lubricant leaksMoving parts encrusted with raw materials or debrisDisorderly wiring, hoses, etc.Equipment mechanisms hidden or difficult to accessWorkplace disorderA belief that conditions cannot improve

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Eliminating BreakdownsWhy machines failDisregard for basic needs (housekeeping, lube..) Incorrect operating conditionsLack of skill or knowledge of operatorMachine deteriorationRoutineAcceleratedDesign deficiency*

Eliminating BreakdownsTwo kinds of breakdownsFunction loss (function completely lost) - SporadicFunction reduction (works, but with loss of speed or quality) - ChronicTwo kinds of breakdown maintenancePlanned (pre-emptive)Unplanned (firefighting)

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TPM and SafetySafety 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 missesSafety should always be the #1 priority

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Advisory Team - ResponsibilitiesGuide & champion TPM implementationAssess current equipment OEE and develop a process for measuring the 6 big lossesDevelop a TPM master planSet plant-wide standards for TPM implementationMonitor and evaluate progress

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Equipment Improvement Teams - ResponsibilitiesReturn equipment to near new condition Investigate and reduce the big 6 equipment lossesTransfer routine maintenance skills to operatorsSet standards for routine maintenance and inspections by operatorsOrganize the work area for more effective/efficient maintenance

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Review of TPMs benefitsFor the companyHigher Overall Equipment EffectivenessLess firefighting to repair machinesLower operating costsBetter able to meet commitments to customersImproved ability to compete in the world marketplace

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Review of TPMs benefitsFor employeesLess pressure on maintenance for urgent repairsLess pressure on production to recover from breakdown lossesBetter cooperation between maintenance, production, and other departmentsReduced chance of accidents Higher job satisfactionImproved job security

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