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Total Productive Maintenance (TPM)

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Presentation on theme: "Total Productive Maintenance (TPM)"— Presentation transcript:

1 Total Productive Maintenance (TPM)
Chapter 6 Total Productive Maintenance (TPM)

2 Total Productive Maintenance
Outcomes Understand the basics of total productive maintenance (TPM) Learn the prerequisites of TPM Learn the main components of TPM Understand autonomous maintenance and preventative maintenance Learn what is involved in a TPM implementation plan IT-465 Lean Manufacturing

3 IT-465 Lean Manufacturing
What is TPM It is a method for continuously improving the effectiveness of production equipment or manufacturing processes through the involvement of all people in the organization IT-465 Lean Manufacturing

4 IT-465 Lean Manufacturing
Definition TPM – A company wide, team-based effort to improve output quality through equipment care and to improve overall equipment effectiveness Total All employees are involved Aims to eliminate all accidents, defects, and breakdowns Productive Actions performed during production Troubles for production are minimized Maintenance Keep in good condition Improve Overall Equipment Effectiveness (OEE) IT-465 Lean Manufacturing

5 Customer Satisfaction
The goal of TPM is to maintain equipment so it will be able to achieve 100% on-demand availability for immediate use by the next process or customer. Equipment breakdowns, unplanned downtime Scrap/rework Reduced productivity Equipment start-up losses Set-up time IT-465 Lean Manufacturing

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TPM Origins Actually started here in the U.S. American manufacturing’s neglected asset TPM Rule #1: Issues relating to job security, responsibilities, classifications, and union support must be resolved. TPM Rule #2: Success depends on daily activities, culture. IT-465 Lean Manufacturing

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TPM Goal Maximize Overall Equipment Effectiveness by minimizing equipment-related losses. Provide a system of comprehensive maintenance for the life cycle of equipment. Involve departments that plan, design, use, and maintain the equipment. IT-465 Lean Manufacturing

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Reactive vs. Proactive Reactive Putting out fires Getting it out the door Customer “needed it yesterday” Building it “just in case” Total Productive Maintenance is Proactive Preventative maintenance – maintain to prevent breakdowns Predictive maintenance – schedule maintenance based on Mean Time To Failure (MTTF) IT-465 Lean Manufacturing

9 IT-465 Lean Manufacturing
5 TPM Principles Improve Overall Equipment Effectiveness (OEE) Improve operators in daily maintenance Improve maintenance efficiency and effectiveness Train all personnel Establish early equipment management and maintenance prevention programs TPM Prerequisites Must be measuring OEE 5S workplace organization IT-465 Lean Manufacturing

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Main Components of TPM Autonomous maintenance – operators take ownership of equipment and conduct regular cleaning, lubricating and minor maintenance themselves. Strengthened preventive maintenance system – includes scheduled, predictive and condition-based maintenance programs. IT-465 Lean Manufacturing

11 IT-465 Lean Manufacturing
TPM Results Improved quality Improved productivity Improved delivery Reduced inventory Improved team member job satisfaction TPM Rule #3: A partnership must be developed between mfg, maintenance, & eng. which fosters an atmosphere of eqpt ownership. IT-465 Lean Manufacturing

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TPM Rule #4 The key to an effective PM component within the TPM initiative is the machine operators. Up to 75% of breakdowns can be detected and prevented by well trained operators. IT-465 Lean Manufacturing

13 Implementation Prerequisites
Top management commitment 5S implementation and team building Dedicated people (Project Champions) Flexible, cross-trainable workers. IT-465 Lean Manufacturing

14 Maintenance Strategies
Breakdown Preventative Predictive Corrective or Improvement Maintenance Prevention IT-465 Lean Manufacturing

15 Autonomous Maintenance
7 Steps to Establish an Autonomous Maintenance System Initial cleaning Address the causes and spread of contamination Develop cleaning, lubrication and bolt tightening/inspection standards General inspection training Autonomous maintenance Workplace organization standards Full implementation of autonomous maintenance IT-465 Lean Manufacturing

16 Preventative Maintenance/Maintenance Prevention
Reason for Preventative Maintenance Improve OEE by reducing downtime Extend Equipment life – protect investment Increased reliability reduces inventory for JIT Reduced energy/consumable cost Reduced spare parts inventory Maintenance Prevention Design to prevent need for maintenance 95% of equipment’s Life Cycle cost is determined in the design phase Requires teamwork of design engineers, maintenance technicians and operators. IT-465 Lean Manufacturing

17 Improvement Measurements
Equipment breakdowns Scrap/rework Reduced productivity Equipment start-up losses IT-465 Lean Manufacturing

18 Overall Equipment Effectiveness
OEE is the product of the three measurements below. Equipment Availability Measures how often eqpt is not producing Equipment Efficiency Performance Measures actual machine cycle time Equipment Quality Performance Compares the # of good pieces produced/total number produced IT-465 Lean Manufacturing

19 Equipment Availability (EA)
EA = Scheduled Production Time - Unplanned Downtime Scheduled Production Time Since, Uptime = Scheduled Production Time – Unplanned Downtime Then, EA = Uptime IT-465 Lean Manufacturing

20 Equipment Efficiency Performance (EEP)
EEP = (Standard Cycle Time) X (# of pcs Produced) Uptime IT-465 Lean Manufacturing

21 Equipment Quality Performance (EQP)
EQP = Total # Produced – Total # Defective Total # Produced Since, # of good pieces = Total # Produced – Total # Defective Then, EQP = # of Good Pieces IT-465 Lean Manufacturing

22 Overall Equipment Effectiveness (OEE)
OEE = (EA) X (EEP) X (EQP) Current World Class benchmarks for these are: EA = 90%, EEP = 95%, EQP = 99% OEE = 85% IT-465 Lean Manufacturing

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Summary TPM can significantly improve a plant’s quality, productivity, and product delivery TPM can generate culture changes in a plant. The only long term competitive advantage any company can have is its people. IT-465 Lean Manufacturing

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Conclusion TPM implementation depends on condition of equipment, work culture, equipment management, and maintenance effectiveness. TPM Benefits Reduced equipment downtime Increased equipment productivity Increased plant capacity Lower maintenance and production costs Approaching zero equipment caused defects Enhanced job satisfaction Increased Return-on-investment IT-465 Lean Manufacturing

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