Presentation on theme: "Total Productive Maintenance and FTM From Werardt"— Presentation transcript:
1Total Productive Maintenance and FTM From Werardt A presentation by Werardt Systemss P Ltd
2Why TPM? Increases Productivity Labor productivity, and Break down reductionImproves Quality byReducing the Defects in processesReducing Defects in productsReducing Customer complaints
3Why TPM? Reduces Cost Reduction in man power Maintenance cost reductionEnergy ConservationDeliveryStock reductionInventory turnover increaseSafety EnvironmentImprovement Ideas increaseSmall Group meetings increase
4Why TPM? Financial Return on Investment (ROI) after 2 to 3 years Break even on initial TPM project – Less than one yearReduction in absenteeism, as work place is enriched
5TPM GoalsZero unplanned DowntimeZero DefectsZero failureZero variabilityReduced Idle time on machinesZero AccidentsMaximized P.M. ComplianceThus Maximizing OEEFTM puts you on the road to achieve these Goals in a Simple, Better and Faster way !
6The Pillars of TPM1 Kobetsu Kaizen - Individual Improvements2 Jishu-Hozen - Autonomous Maintenance3 Planned Maintenance4 Quality Maintenance5 Education and Training6 Safety and Environment7 Office TPM8 Development ManagementTPM is a cultural change and FTM supplements it in Information management
7Some “Facts” about TPM & Maintenance Maintenance can generally account for a major portion of today’s manufacturing costsHence when it comes to TPM implementation the Maintenance department generally takes the leadGenerally upto 25% of maintenance cost is wasted or not knownEmergency repair jobs are at least three times more expensive than the same repair done a pre-planned basis.Hence TPM & Maintenance go hand-in-hand
8How to achieve Zero Breakdowns? RCFA - Root Cause Failure AnalysisMaking P.M. effective and dynamicCondition & Time Based MaintenanceDoing Why-Why Analysis and maintaining 6W2HImproving the Reliability of workReducing Idle time on repairsCondition Monitoring and InspectionAutonomous Maintenance activitiesFTM is very strong in this area !
9The FTM Steps to Success Awareness : Understanding your activities, Identifying Critical, Essential and Desirable requirementsBusiness Process Optimization : What processes do you follow to achieve your objectives? Who is doing what? Are they trained for the Job? Are required skills available?Quantification : How many and which type of Jobs do you do? To focus on the type of work being done, how much is reactive and how much is proactive?Benchmarking : FTM helps in devising and defining your Key measuring parameters or KPI’s that help in ImprovementsPerformance Review : And most importantly devising a post implementation review mechanism to monitor progress
10Maintenance Prevention Design Facilitating autonomous maintenance or Jishu Hozen, through Activity based PM, and feedback on machine behaviorApplying Kaizen activities to monitor ImprovementsIncreasing the ease of operation, make it easy from information and work point of viewImproving skills through need based training programs and easy availability of historyImproving maintainability through condition monitoring and reliable operationsImproving safety through awarenessApplying FTM feedback !
11Key Result Areas 1. Improving human resources Operators’ ability to perform Jishu-HozenMaintenance employees’ ability to perform quality & reliable maintenanceProduction engineers’ ability to execute maintenance free equipment plan2. Improving Plant & MachineryMaximizing UptimeIncreased Plant valueAchieving TPR - Total Plant Reliability
12FTM directly and indirectly helps you in achieving the above Key Result Areas3. Improving the corporate cultureFrom authoritarian to participative managementInvolving everyone in CIP4. Reducing lossesDown time lossesSpeed lossesDefect lossesFTM directly and indirectly helps you in achieving the above