1. Total Productive Maintenance Dr Neil Towers Fashion Operations Management

2. Learning Objectives To understand the concept of Total Productive Maintenance (TPM) To be able to assess the impact of failure for a fashion operation

3. Definition “the maintenance management carried out by all employees through small group activities that recognises the importance of reliability, service and efficient operation” Adapted from Slack et al, 3 rd ed, 2001, p659

4. Why systems fail Design failures Facilities failures Staff failures Failures inside the operation Supply failures Customer failures

5. Causes of Failure Design failures Facilities failures Staff failures Supplier failures Customer failures

6. How failure is detected and analysed Failure detection mechanisms include: -in-process checks; -machine-diagnostic checks; -point-of-departure interviews. Failure analysis procedures include: -accident investigation; -failure mode-and-effect analysis; -fault-tree analysis.

7. 5 Goals of TPM Improve equipment effectiveness Achieve autonomous maintenance Plan maintenance Train all staff in relevant maintenance skills Achieve early equipment management

8. Recovery strategies for dealing with failure Plan Discover Act Learn Failure analysis - possibilities Recovery planning - procedures The facts - what has happened? The consequences Inform, contain and follow up Find the root cause Prevent it happening again

9. Failure analysis Accident investigation Product liability Complaint analysis Critical incident analysis Failure mode and effect analysis

10. Assessing Failure Failure rate Reliability Availability

11. How failure is measured Time Wear-out stage Normal-life stage Infant- mortality stage Failure rate

12. Fashion Operations issues Extended geographic supply chains –Long distances –High transit times Multiple intermediaries –Agents, Wholesalers, Logistics operators Customer Service Intensive selling season –Compressed timescale High customer expectations –Focus on satisfaction