1. Total Productive Maintenance and Maintenance Management
Lean Manufacturing Series

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

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

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

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

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

8. The Strategic Importance of Maintenance and Reliability
Failure has far reaching effects on a firm’s
operation
reputation
profitability
customers
product
employees
profits
The effect of failure on the listed items should be discussed. A point to make is that the cost of failure implies more than simply “this unit doesn’t work.” It reduces the likelihood of return customers in many ways.

9. Tactics for Reliability and Maintenance
Reliability Tactics
improving individual components
providing redundancy
Maintenance Tactics
implementing preventive maintenance
increasing repair capabilities
You might discuss the meaning of redundancy.

10. Organizing the Maintenance Function
Centralized maintenance department
Does all maintenance (PM & breakdown)
Decentralized maintenance department
Useful if different equipment used in different areas of company
Contract maintenance
Used if little equipment or expertise
Operator ownership approach
Ask students to identify some of the pros and cons of the various possibilities.

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