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Total Productive Maintenance TPM. AGENDA TPM Agenda »Introduction To TPM »Why – Benefits? »Typical Maintenance Strategies »What Does TPM Look Like? »How.

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Presentation on theme: "Total Productive Maintenance TPM. AGENDA TPM Agenda »Introduction To TPM »Why – Benefits? »Typical Maintenance Strategies »What Does TPM Look Like? »How."— Presentation transcript:

1 Total Productive Maintenance TPM

2 AGENDA TPM

3 Agenda »Introduction To TPM »Why – Benefits? »Typical Maintenance Strategies »What Does TPM Look Like? »How to Start Using TPM »Sustaining »Summary / Questions AGENDA TPM

4 INTRODUCTION TPM

5 What is TPM? »TPM is a method for continuously improving the effectiveness of production equipment and processes Introduction TPM »By improving On Demand availability of the equipment, through improved maintenance How is this Accomplished?

6 How is this Different from Other Maintenance Programs? »Primary difference between TPM and most maintenance programs is the involvement of the machine operator as a front line defense against… Introduction TPM –Equipment breakdowns and other unplanned downtime –Scrap and rework caused by poor equipment performance –Reduced productivity due to running at reduced speeds, idling, or stoppages requiring operator attention –Equipment startup losses

7 Brief History of TPM »Preventative maintenance originated in the United States in 1940s Introduction TPM »Japanese auto manufacturers studied these methods in the 1950s »First true TPM initiative developed by Nippondenso in the late 1960s »First true TPM in the United States developed by Kodaks Tennessee Eastman facility in 1987

8 Why is TPM Important? TPM

9 Why is TPM Important TPM

10 Why is TPM Important TPM

11 WHY??? »Maximizes the productivity of equipment for its entire life cycle Why is TPM Important – Benefits TPM »Extends equipment life »Increases the amount of time equipment can be doing what we need it to do »Builds / Trains a workforce that can most effectively help the organization best utilize its equipment

12 WHY??? To reduce Waste? »Equipment Breakdowns Why is TPM Important – Benefits TPM »Setup and Adjustment Delays »Idling and minor stoppages »Reduced Speed »Process Defects »Reduced Yield

13 Typical Maintenance Strategies TPM

14 Types Typical Maintenance Strategies TPM »Reactive »Preventive »Predictive »Corrective Maintenance »Maintenance Elimination »All of these can have a place, yet some better than others

15 Most Common Strategy? Typical Maintenance Strategies TPM If it aint broke, dont fix it. »Reactive Maintenance

16 Reactive Maintenance = 55% Typical Maintenance Strategies TPM »Advantages Low cost Less staff »Disadvantages Increased cost due to unplanned downtime of equipment Increased labor cost, especially if overtime is needed,cost involved with repair or replacement of equipment. Possible secondary equipment or process damage from equipment failure. Inefficient use of staff resources.

17 Can we get better? Typical Maintenance Strategies TPM »Preventive Maintenance Time or Machine cycle based maintenance functions

18 Preventive Maintenance = 31% Typical Maintenance Strategies TPM »Developed by US Navy »Advantages Cost effective in many capital-intensive processes Flexibility allows for the adjustment of maintenance schedules Increased component life cycle Energy savings Reduced equipment or process failure Estimated 12% to 18% cost savings over reactive maintenance program. »Disadvantages Catastrophic failures still likely to occur Labor intensive Includes performance of unneeded maintenance Potential for incidental damage to components in conducting unneeded maintenance.

19 Anything Better? Typical Maintenance Strategies TPM »Predictive Maintenance Maintenance functions based on feedback, predicting that something needs to be done.

20 Predictive Maintenance = 12% Typical Maintenance Strategies TPM »Advantages Increased component operational life/availability. Allows for preemptive corrective actions. Decrease in equipment or process downtime. Decrease in costs for parts and labor. Better product quality. Improved worker and environmental safety. Improved worker morale. Energy savings. Estimated 8% to 12% cost savings over preventive maintenance program. »Disadvantages Increased investment in diagnostic equipment. Increased investment in staff training. Savings potential not readily seen by management.

21 More? Typical Maintenance Strategies TPM »Corrective Maintenance Modifying a piece of equipment such that it will last longer.

22 More? Typical Maintenance Strategies TPM »Maintenance Elimination Removing or reducing the need for maintenance to occur

23 What Does TPM Look Like? TPM

24 TPM Implemented? What Does TPM Look Like? TPM »Machine Operators are trained to do much of the maintenance operations, and its part of their Standard Work

25 TPM Implemented? What Does TPM Look Like? TPM »Tools necessary are readily available

26 TPM Implemented? What Does TPM Look Like? TPM »Equipment modified such that easy to keep clean, easy to see when maintenance is required. BeforeAfter

27 TPM Implemented? What Does TPM Look Like? TPM »More examples of easily cleaned and seen Before After Filtered Air

28 TPM Implemented? What Does TPM Look Like? TPM »More examples of easily cleaned and seen Before After

29 TPM Implemented? What Does TPM Look Like? TPM »Equipment modified such that easy to maintain

30 How to Implement? TPM

31 How To…. How To Implement? TPM 1. Select Equipment to work on 2. Begin with 5Sing, Initial Clean Up 3. Define Machine Operator Maintenance Tasks Modify equipment to facilitate tasks 4. Define Maintenance Technician Tasks Provide informative tools to assist 5. Sustain

32 How To…. How To Implement? | Equipment Selection TPM 1. Select Equipment to work on…. Equipment that is giving you problems with… Unplanned downtime Excessive quality problems Excessive repair costs Premature end of life failures Running slower than design to prevent breakdowns

33 How To…. How To Implement? | Equipment Selection TPM 2. 5S Event…. Improves ability to perform regular inspections Allows the discovery of potential problems Log problems and potential problems and develop an immediate action plan Mark all lubrication, fluid connections and directions, etc Paint equipment

34 How To…. How To Implement? | Equipment Selection TPM 3. Defining Machine Operator Tasks Develop Standards and Checklists Cleaning Lubrication Visual Checks Procedures to keep equipment as new

35 How To…. How To Implement? | Equipment Selection TPM 3. Make Machine Operator maintenance tasks easier/quicker Easy to see when things need to be maintained Lubrication needs become obvious to operator Routine cleaning operations easier Machine disassembly minimized Automate maintenance when possible Clear signals when maintenance is needed

36 How To…. How To Implement? | Equipment Selection TPM 3. Defining Machine Operator Tasks (cont.) Train Operators on…. Visual checks Hydraulics Electrical / electronics Mechanical drive systems Complex lubrication Safety Procedures for minor repair and replacement Criteria delineating operator and technician approved activities

37 How To…. How To Implement? | Equipment Selection TPM 3. Defining Machine Operator Tasks (cont.) Implement Daily Operator Activities Review checklists with operators Ensure operator training is complete Finalize checklist schedules

38 How To…. How To Implement? | Equipment Selection TPM 4. Define Maintenance Tech Tasks (Reactive) Provide Tech support to operator questions Provide clear communication path Spare Parts Program Equip Manufacturer recommendations Breakdown History Data Kanban

39 How To…. How To Implement? | Equipment Selection TPM 4. Define Maintenance Tech Tasks (Preventive) Eliminate Equipment Deterioration Scheduled general inspections Equipment overhauls Triggered by checklists Identify and Resolve Chronic Problems Breakdown history log Root cause analysis methods 5 Why analysis

40 How To…. How To Implement? | Equipment Selection TPM 4. Define Maintenance Tech Tasks (Predictive) Develop and Analyze Equipment History Plot failure history Correlate with Equipment Quality Performance Determine Equipment Parameters That Predict Failure Use information from equipment manufacturer Oil, vibration, temperature analysis Develop Equipment Monitoring Systems Ensure appropriate accuracy and tolerance Lease equipment to ensure usability before purchase

41 Sustain TPM

42 Sustaining…. Sustain TPM »Measuring progress / status is key to sustaining »Primary Measurement tool is OEE »OEE – Overall Equipment Effectiveness, is measured…. OEE = Equip Availability X Performance Efficiency X Quality Rate »Audit machine operators standard work »Audit maint techs standard work

43 Summary TPM

44 »TPM is a method for continuously improving the effectiveness of production equipment and processes Summary TPM »By improving On Demand availability of the equipment, through improved maintenance »With a primary focus on involving machine operators in routine maintenance »And making that maintenance easily seen, easily done, and effective

45 Q&A TPM


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