1 Total Productive Maintenance and Maintenance Management

2 Outline What is Total Productive Maintenance What is Total Productive Maintenance Origins of TPM Origins of TPM TPM Principles TPM Principles Components of TPM Components of TPM Autonomous Maintenance Autonomous Maintenance Planned Maintenance Planned Maintenance Equipment & Process Improvement Equipment & Process Improvement Early Management of New Equipment Early Management of New Equipment Process Quality Management Process Quality Management TPM in the Office TPM in the Office Implementing TPM Implementing TPM TPM Benefits TPM Benefits Maintenance Management & Strategy Maintenance Management & Strategy

3 What is TPM A company-wide team-based effort to build quality into equipment and to improve overall equipment effectiveness A company-wide team-based effort to build quality into equipment and to improve overall equipment effectiveness Total Total all employees are involved all employees are involved it aims to eliminate all accidents, defects and breakdowns it aims to eliminate all accidents, defects and breakdowns Productive Productive actions are performed while production goes on actions are performed while production goes on troubles for production are minimized troubles for production are minimized Maintenance Maintenance keep in good condition keep in good condition repair, clean, lubricate repair, clean, lubricate

4 Autonomous Maintenance 7 steps are implemented to progressively increase operators knowledge, participation and responsibility for their equipment 7 steps are implemented to progressively increase operators knowledge, participation and responsibility for their equipment 1. Perform initial cleaning and inspection 1. Perform initial cleaning and inspection 2. Countermeasures for the causes and effects of dirt and dust 2. Countermeasures for the causes and effects of dirt and dust 3. Establish cleaning and lubrication standards 3. Establish cleaning and lubrication standards 4. Conduct general inspection training 4. Conduct general inspection training 5. Carry out equipment inspection checks 5. Carry out equipment inspection checks 6. Workplace management and control 6. Workplace management and control 7. Continuous improvement 7. Continuous improvement

5 Early Management of New Equipment Objective: establish systems to shorten Objective: establish systems to shorten new product or equipment development new product or equipment development start-up, commissioning and stabilization time for quality and efficiency start-up, commissioning and stabilization time for quality and efficiency New equipment needs to be: New equipment needs to be: easy to operate easy to operate easy to clean easy to clean easy to maintain and reliable easy to maintain and reliable have quick set-up times have quick set-up times operate at the lowest life cycle cost operate at the lowest life cycle cost

6 7: Develop Equipment Management Program The tools of Total Quality Management and Continuous Improvement are applied to the management and improvement of equipment The tools of Total Quality Management and Continuous Improvement are applied to the management and improvement of equipment Form project teams Form project teams Select model equipment Select model equipment identify equipment problems identify equipment problems analyze equipment problems analyze equipment problems develop solutions and proposals for improvement develop solutions and proposals for improvement

7 The Strategic Importance of Maintenance and Reliability Failure has far reaching effects on a firm’s Failure has far reaching effects on a firm’s operation operation reputation reputation profitability profitability customers customers product product employees employees profits profits

8 Tactics for Reliability and Maintenance Tactics for Reliability and Maintenance Reliability Tactics Reliability Tactics improving individual components improving individual components providing redundancy providing redundancy Maintenance Tactics Maintenance Tactics implementing preventive maintenance implementing preventive maintenance increasing repair capabilities increasing repair capabilities

9 Centralized maintenance department Centralized maintenance department Does all maintenance (PM & breakdown) Does all maintenance (PM & breakdown) Decentralized maintenance department Decentralized maintenance department Useful if different equipment used in different areas of company Useful if different equipment used in different areas of company Contract maintenance Contract maintenance Used if little equipment or expertise Used if little equipment or expertise Operator ownership approach Operator ownership approach Organizing the Maintenance Function

10 Increasing Repair Capabilities:Features of A Good Maintenance Facility Well-trained personnel Well-trained personnel Adequate resources Adequate resources Ability to establish a repair plan and priorities Ability to establish a repair plan and priorities Ability and authority to do material planning Ability and authority to do material planning Ability to identify the cause of breakdowns Ability to identify the cause of breakdowns Ability to design ways to extend MTBF Ability to design ways to extend MTBF