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
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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
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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)
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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
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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.
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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.
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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)
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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
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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.
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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.
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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.
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13. Implementation Prerequisites
Top management commitment
5S implementation and team building
Dedicated people (Project Champions)
Flexible, cross-trainable workers.
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14. Maintenance Strategies
Breakdown
Preventative
Predictive
Corrective or Improvement
Maintenance Prevention
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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
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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.
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17. Improvement Measurements
Equipment breakdowns
Scrap/rework
Reduced productivity
Equipment start-up losses
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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
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19. Equipment Availability (EA)
EA = Scheduled Production Time - Unplanned Downtime
Scheduled Production Time
Since, Uptime = Scheduled Production Time – Unplanned Downtime
Then, EA = Uptime
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20. Equipment Efficiency Performance (EEP)
EEP = (Standard Cycle Time) X (# of pcs Produced)
Uptime
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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
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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%
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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.
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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
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