Total Productive Maintenance

Total Productive Maintenance (TPM)
BY Neeraj Kumar
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
Definition
TPM is a company-wide system developed to maintain, monitor, and improve all capital assets of a company. For production it is a system that maximizes equipment effectiveness and maintains product flow. TPM is not just about maintenance. It is about getting the most overall benefit from your equipment over the life of the equipment. Implementing it throughout a plant correctly will take several years.
No Tolerance for Breakdowns

Equipment breakdowns impact
Customer service Production costs Maintenance costs Effectiveness of manufacturing cells or flow lines
Breakdowns result in chaos
Benefits of TPM to the Company

Improved plant productivity and capacity Lower operating costs Improved equipment lifespan Better ability to satisfy customers
Bottom Line: TPM increases long-term benefits
Benefits of TPM for Operators & Maintenance Personnel

Increased skills through additional training Better job satisfaction
Operators More involvement in solving annoying equipment problems Maintenance More challenging work
Better job security
Shift in Attitudes
Operator
Maintenance
Operator Maintenance
I use
I maintain & I fix
We maintain
Conventional
TPM
5 Pillars of TPM
1. Improvement activities designed to increase equipment effectiveness (OEE) 2. Autonomous maintenance program performed by equipment operators 3. A planned maintenance system 4. Training to improve operation & maintenance skills 5. Effective new equipment design and startup
TPM Emphasizes Prevention

Three Principles of Prevention 1. Maintain normal conditions 2. Early discovery of abnormalities
a) Operator b) Maintenance
3. Prompt response
10
The Six Big Equipment Losses

1. 2. 3. 4. 5. 6. Breakdowns Setups and adjustment Idling and minor stoppages Speed Quality defects and rework Start-up (loss of yield)
11
Six Big Equipment Losses lead to loss of

operation reputation profitability customers product employees profits
Overall equipment effectiveness = Availability x Performance rate x Quality rate (OEE)
Breakdown Setup and adjustment Others
Idling & minor stoppages Reduced speed
Quality defects & rework Start-up yield
Operation time (Scheduled time available Downtime) Availability = ______________________________________________ x 100 Scheduled time available
processed amount x ideal cycle time Performance rate = _____________________________ Operation time
14
Eliminating Breakdowns
Workplace Conditions Contribute to Losses
Filthy equipment Oil and lubricant leaks Moving parts encrusted with raw materials or debris Disorderly wiring, hoses, etc. Equipment mechanisms hidden or difficult to access Workplace disorder A belief that conditions cannot improve
15
Why machines fail Disregard for basic needs (housekeeping, lube..) Incorrect operating conditions Lack of skill or knowledge of operator Machine deterioration
Design deficiency
Routine Accelerated
16
Two kinds of breakdowns
Function loss (function completely lost) Sporadic Function reduction (works, but with loss of speed or quality) - Chronic
Two kinds of breakdown maintenance

Planned (pre-emptive) Unplanned (firefighting)
17
TPM and Safety

Safety is the cornerstone of production activities Accidents usually occur when unsafe behavior is combined with unsafe conditions For every major accident there are 29 minor accidents and 300 near misses Safety should always be the #1 priority
18
Advisory Team - Responsibilities

Guide & champion TPM implementation Assess current equipment OEE and develop a process for measuring the 6 big losses Develop a TPM master plan Set plant-wide standards for TPM implementation Monitor and evaluate progress
19
Equipment Improvement Teams Responsibilities

Return equipment to near new condition Investigate and reduce the big 6 equipment losses Transfer routine maintenance skills to operators Set standards for routine maintenance and inspections by operators Organize the work area for more effective/efficient maintenance
20
Review of TPMs benefits

For the company
Higher Overall Equipment Effectiveness Less firefighting to repair machines Lower operating costs Better able to meet commitments to customers Improved ability to compete in the world marketplace
21
Review of TPMs benefits

For employees
Less pressure on maintenance for urgent repairs Less pressure on production to recover from breakdown losses Better cooperation between maintenance, production, and other departments Reduced chance of accidents Higher job satisfaction Improved job security

Total Productive Maintenance

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Total Productive Maintenance (TPM)

No Tolerance for Breakdowns

Breakdowns result in chaos

Benefits of TPM to the Company

Bottom Line: TPM increases long-term benefits

Benefits of TPM for Operators & Maintenance Personnel

Better job security

I maintain & I fix

TPM Emphasizes Prevention

The Six Big Equipment Losses

Six Big Equipment Losses lead to loss of

Overall equipment effectiveness = Availability x Performance rate x Quality rate (OEE)

Breakdown Setup and adjustment Others

Idling & minor stoppages Reduced speed

Quality defects & rework Start-up yield

Two kinds of breakdown maintenance

TPM and Safety

Advisory Team - Responsibilities

Equipment Improvement Teams Responsibilities

Review of TPMs benefits

Review of TPMs benefits

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