What is Total Productive

Maintenance?

TPM is a plant improvement methodology which enables continuous and rapid improvement of the manufacturing process through use of employee involvement, employee empowerment, and closed-loop measurement of results.

Breakdown of TPMTOTAL = All encompassing by maintenance and production individuals working togetherPRODUCTIVE = Production goods and services that meet or exceed customers’ expectationsMAINTENANCE = Keeping equipment and plant in as good as or better than the original conditions at all times

Goals of TPM1. Aims at getting the most effective use of

equipment2. Builds a comprehensive PM system3. Brings together people from all departments

concerned with equipment4. Requires the support and cooperation of everyone

from top managers down5. Promotes and implements PM activities based on

autonomous small group activities.6. Maintaining Equipment for life7. Encouraging input from all employees8. Using teams for continuous improvement

TPM Basic Policy and Objectives

o To maximize overall equipment effectiveness (Zero breakdowns and failures, Zero accident, and Zero defects etc) through total employee involvement

o To improve equipment reliability and maintainability as contributors to quality and to raise productivity

o To aim for maximum economy in equipment for its entire life

o To cultivate equipment-related expertise and skills among operators

o To create a vigorous and enthusiastic work environment

TPM Corporate policy • To aim for world-class maintenance, manufacturing

performance and quality

• To plan for corporate growth through business leadership

• To promote greater efficiency through greater flexibility

• Revitalize the workshop and make the most of employee talents

TPM - Evolution

• Breakdown maintenance

• Preventive maintenance (PM)

• Productive maintenance

• Total productive maintenance

12 TPM Development Program Steps

Preparation

1. Formally announce the decision to introduce TPM2. Conduct TPM introductory education and publicity

campaign3. Create TPM promotion organization4. Establish basic TPM policy and goals5. Draft a master plan for implementing TPM

Introduction6. Kick off TPM initiatives (to cultivate the atmosphere to raise morale, inspiration and dedication)

Implementation

7.Build a corporate constitution designed to maximize the effectiveness of facilities

- Conduct focused improvement activities - Establish and deploy autonomous maintenance program - Implement planned maintenance program - Conduct operation and maintenance skills training

8.Build an early management system for new products and equipment

9. Build a quality maintenance system

10. Build an effective administration and support system

11. Develop a system for managing health, safety, and the environment

Consolidation12. Sustain a full TPM implementation and raise levels (Prize)

Five fundamental TPM activities

1. Autonomous maintenance2. Equipment improvement3. Quality maintenance4. MP(Maintenance Prevention) system-

building5. Education and training

Pillars of TPM

PILLAR 1 - Autonomous MaintenanceA collaborative team activity involving production, maintenance, and engineering Maintaining Basic conditions on shop floor & in Machines. All over participation through TPM Circles.

PILLAR 2 - Focused ImprovementImprovement on every one’s activity.Improvement is to eliminate Production losses and cost reduction. Improvement in Reliability, Maintainability, and cost.

PILLAR 3 - Planned MaintenanceLogical analysis “Real causes for real counter measures”.Focus on Prevention. It is aimed to have trouble free machines and equipments producing defect free products for total customer satisfaction. Example: Preventive Maintenance, Breakdown Maintenance, etc.,

Six steps in Planned maintenance :1.Equipment evaluation and recoding present status.2.Restore deterioration and improve weakness.3.Building up information management system.4.Prepare time based information system, select equipment, parts and members and map out plan.5.Prepare predictive maintenance system by introducing equipment diagnostic techniques.6.Evaluation of planned maintenance.

PILLAR 4 - Quality Maintenance

-Developing perfect machine for perfect Quality.-Eliminating In – Process defects and custom complaints.

PILLAR 5 - Education & Training-Skills development for uniformity of work practices on machines.-Skills for Zero defects, Zero breakdowns & Zero accidents.-Multi Skilled employees in all departments

PILLAR 6 - Development Management

-Developing machines for “high equipment effectiveness”.-Quick process for developing new products. Example: KAIZEN

PILLAR 7 - Safety, Health & Environment

-Zero accidents and Zero hazards at works.-Zero Pollution at Plant and Environment.

PILLAR 8 - Office TPM

-Office TPM must be followed to improve productivity, efficiency in the administrative functions and identify and eliminate losses. This includes analyzing processes and procedures towards increased office automation

TPM and Traditional MaintenanceReactive maintenance inherently wasteful and ineffective with following disadvantages:

1.No warning of failure2.Possible safety risk3.Unscheduled downtime of machinery4.Production loss or delay5.Possible secondary damage

Need for:-Stand-by machinery-A stand-by maintenance team-A stock of spare parts

Costs include:

-Post production-Disrupted schedule-Repair cost-Stand-by machinery-Spare parts

Real cost of reactive maintenance is more than the cost of maintenance resources and spare parts

Pro-active maintenance (planned, preventive and predictive) more desirable than reactive maintenance

TPM enables or provides:

The traditional maintenance practices to change from reactive to pro-active

A number of mechanisms whereby

Breakdowns are analyzed Causes investigated Actions taken to prevent further breakdowns

Preventive maintenance schedule to be made more meaningful

To ‘free up’ maintenance professionals to: Carry out scheduled and preventive maintenance Gather relevant information as important input to the maintenance system Keep the system up to date

To review cost effectiveness

To develop and operate a very effective maintenance system an integral part of manufacturing

Establish and maintain a clean, neat and tidy workplace

Translation of 5 Japanese S’s

1. Seiso => Shine / Cleanliness (Thoroughly clean the workplace)

Advantages:– Pleasant and safer workplace and improved morale– No wear, corrosion and failure of machinery due to dirt and debris– Easy detection of oil leakage and spilage– Psychological effects for improved reactions and performances– Reduced hazards and more visible warning signs

2.Seiri => Sort / Arrangement

(Eliminate unnecessary items)Better arrangement for ease of access and use of:-Facilities, tools, fixtures and materials etc.which brings substantial benefits

3.Seiton => Set In Order / Neatness

Efficient and effective storage method-Defined location for storage of every facility required for production process-Encourage people to return the facility after use

4.Shitsuke => Sustain / Discipline

(Sustain new status quo ‘everything in its place’)Required to ensured that facilities are:

-Returned in proper location after use-Kept clean and tidy-Repaired / replaced if damaged

5.Seiketsu => Standardize / Order

Order and control to be established for:

-The above procedures and mechanisms-Introduction of CAN DO activities at early stage-Part of the company culture

Tangible and Intangible Benefits of TPM Tangible benefits:

1.Productivity up due to Sudden breakdowns down Overall facilities effectiveness up

2.Process defect rate down3.Customer compliant/claims down4.Products and work-in-process down5.Shutdown accidents down6.Pollution incidents down7.Improvement suggestions up

Tangible benefits (contd.):

8.Financial losses drop due to reduction in breakdowns9.Repair costs drop10.Maintenance labour-hours reduce11.Energy costs reduce12. Company’s manufacturing profit ratio up

Intangible benefits:1.Achieving full-self management2.Operators have ownership of their equipments3.They look after it by themselves without direction

4.Eliminating breakdowns and defects5.Growing confidence and ‘can-do’ attitude6.Making previously dirty and oily workplaces to a unrecognizably clean, bright and lively7.Giving better image to the visitors and thereby getting more orders

Why is TPM so popular and important ?Three main reasons:

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

Why is TPM so popular and important ?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 changeConfidence on plant’s product increases

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

What is OEEOEE (overall equipment efficiency) is a “best practices” way to monitor and improve the efficiency of your manufacturing processes

-machines-manufacturing cells-assembly lines

Why use OEE?Productivity Increases of 10-50%

Reduce Unplanned DowntimeReduce Setup and Changeover TimesBetter Management of Resource Allocation, Planning and

SchedulingOperator Productivity IncreasesEfficiency with Automated Data CollectionBetter Root Cause AnalysisImprove Quality, Minimize RejectsIdentify Bottlenecks and ConstraintsImprove On-Time DeliveryManage Operations Pre-emptively & ProactivelyMeasurably Improve Profitability

Why use OEE? OEE is integral to Successful LEAN manufacturing

Used adroitly, Strategic OEE means Millions of $$ of Profits

‘Financial OEE’ becomes a Navigational tool for Success

OEE = Quality, Reliability and Manufacturing Best Practices

World Class OEE = “Least Price Provider” of products

Why use OEE?OEE is about Adding Value

Characteristics of Top Quartile Manufacturing OrganizationsOEE is the visual metric of Total Productive Manufacturing

TPM is integrated to successful LEAN Manufacturing

Constantly improving their ‘Best Ever’ performance

Synergizing every player’s contribution

Effectively Communicating new ideas or conditions

Why is OEE so important?

If you were told that your department was running flat out you might reasonably assume that the equipment was running efficiently and effectively.

What if the equipment only ran for 65% of the time? What if when it ran it ran at 80% of its speed ? What if only 90% of the parts it made are good? Individually these performance measures seem to indicate an

OK piece of equipment, but is it a true picture? What is having an impact on these performance figures?

How do I measure OEE?Overall Equipment Effectiveness

OEE % = Availability x Performance x Quality Shows group or plant output as a percentage of maximum capacityWorld Class = 85% (= 95% x 95% x 95%)

It is not uncommon to > 90%!Availability %

Percentage of scheduled time that the operation is actually operating.

Availability % = Run Time / Scheduled TimePerformance %

Speed at which the Work Center runs as a percentage of its designed speed or ideal cycle time or most often considered the “Standard”.

Performance % = (Parts Made x Standard) / Run Time Quality %

Good Units produced as a percentage of the Total Units Started.

Quality % = Good Units / Units Started