Total Productive Maintenance TPM

AGENDA TPM

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

INTRODUCTION TPM

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

How is this Different from Other Maintenance Programs? Introduction 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… 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 TPM

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

Why is TPM Important? TPM

Why is TPM Important TPM

Why is TPM Important TPM

Maximizes the productivity of equipment for its entire life cycle Why is TPM Important – Benefits WHY??? Maximizes the productivity of equipment for its entire life cycle 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 it’s equipment TPM

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

Typical Maintenance Strategies TPM

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

“If it ain’t broke, don’t fix it”. Typical Maintenance Strategies Most Common Strategy? “If it ain’t broke, don’t fix it”. Reactive Maintenance TPM

Reactive Maintenance = 55% Typical Maintenance Strategies Reactive Maintenance = 55% 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. TPM

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

Preventive Maintenance = 31% Typical Maintenance Strategies Preventive Maintenance = 31% 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. TPM

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

Predictive Maintenance = 12% Typical Maintenance Strategies Predictive Maintenance = 12% 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. TPM

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

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

What Does TPM Look Like? TPM

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

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

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

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

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

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

How to Implement? TPM

1. Select Equipment to work on How To Implement? How To…. 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 TPM

1. Select Equipment to work on…. How To Implement? | Equipment Selection How To…. 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 TPM

Improves ability to perform regular inspections How To Implement? | Equipment Selection How To…. 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 TPM

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

3. Make Machine Operator maintenance tasks easier/quicker How To Implement? | Equipment Selection How To…. 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 TPM

3. Defining Machine Operator Tasks (cont.) Train Operators on…. How To Implement? | Equipment Selection How To…. 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 TPM

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

4. Define Maintenance Tech Tasks (Reactive) How To Implement? | Equipment Selection How To…. 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 TPM

4. Define Maintenance Tech Tasks (Preventive) How To Implement? | Equipment Selection How To…. 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 TPM

4. Define Maintenance Tech Tasks (Predictive) How To Implement? | Equipment Selection How To…. 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 TPM

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 operator’s standard work Audit maint tech’s standard work TPM

Summary TPM

And making that maintenance easily seen, easily done, and effective Summary TPM is a method for continuously improving the effectiveness of production equipment and processes 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 TPM

Q&A TPM