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©2008 Productivity Inc. All Rights Reserved
Introduction to TPM – Objectives and Benefits
September 29, 2008
The Five Pillars of TPM The Five Pillars of TPM TPM TPM TPM
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Cross-Functional, Team-Based Improvement Activities
©2008 Productivity Inc. All Rights Reserved
Textbook Definition
“TPM is a plant improvement methodology which enables continuous and rapid improvement
through use of employee involvement, employee empowerment, and closed-loop measurement of
results.”
©2008 Productivity Inc. All Rights Reserved
TPM Implementation – Nakajima’s 12 Steps1. Announce Top Management’s Decision to Introduce TPM2. Launch Educational Campaign3. Create Organizations to Promote TPM4. Establish Basic TPM Policies and Goals5. Formulate a Master Plan for TPM Development6. Hold TPM “Kickoff”7. Improve Equipment Effectiveness8. Establish an Autonomous Maintenance Program for Operators9. Set-up a Scheduled Maintenance Program for the Maintenance
Department10. Conduct Training to Improve Operation and Maintenance Skills11. Develop Initial Equipment Management Program12. Implement TPM Fully and Aim for Higher Goals
©2008 Productivity Inc. All Rights Reserved
Characteristics of TPM
Optimum relationships between people and equipment/processInvolvement of everyone, from top leadership to shopfloor workersA cross-functional approach, involving all departmentsImplementation through small group teamworkDATA DRIVEN!!!
©2008 Productivity Inc. All Rights Reserved
Two Types of Teams
Manager
Natural teamNatural team
Manager
Natural teamNatural team
CrossCross--functionalfunctional
Definition(s)
Note: The DREADED “M” word is not used!!!
So what does maintenance mean anyway…
Maintenance = The act of maintainingMaintain = To keep in a state of order. To keep in
due (rightful, proper, fitting) condition, operation, or force; keep unimpaired.
©2008 Productivity Inc. All Rights Reserved
Definition(s) cont…Fix and Repair = Maintenance
HOZEN (Maintenance in Japanese) = Maintaining and preserving perfection through Asset Management.
TPM = Total Productive ManagementTPM = Total Productive Manufacturing
©2008 Productivity Inc. All Rights Reserved
TPM Goals
Zero accidents
Minimum life cycle cost
Zero unplanned downtime
Zero speed losses
Zero defects
Zero waste!
©2008 Productivity Inc. All Rights Reserved
Results
Overall Equipment Effectiveness (OEE) Improved
Mean Time Between Failure Improved
Mean Time To Repair Improved
Etc…
©2008 Productivity Inc. All Rights Reserved
Actual “GREEN” Results$60K/ Month Facilities Maintenance Savings
$700K Annual Savings “Other-than-hazardous-waste”
• TPM Process applied to facilities maintenance activities
Plant Air System
Plant Lighting during peak Kilowatt usage
Plant Start-up/Shut-down Procedures
Waste Water Treatment System
Note: Above results since 1998
©2008 Productivity Inc. All Rights Reserved
©2008 Productivity Inc. All Rights Reserved
TPM Is a Paradigm Shift
Old Attitude“I operate, you fix”
“I fix, you design”
“I design, you operate”
Old Attitude“I operate, you fix”
“I fix, you design”
“I design, you operate”
TPM Attitude“We are all responsiblefor our equipment,our plant, andour future”
TPM Attitude“We are all responsiblefor our equipment,our plant, andour future”
©2008 Productivity Inc. All Rights Reserved
Training and Skill Development
©2008 Productivity Inc. All Rights Reserved
Why Training and Skill Development
Operators and Maintenance: • Should possess the training and skills
necessary to carry out all of the required TPM activities so that they have…
A clear understanding of the criteria for judging normal and abnormal conditionsCan be empowered to strictly enforce condition management rulesThe ability to quickly respond to any and all abnormalities
©2008 Productivity Inc. All Rights Reserved
Early Equipment Management (EEM) and Maintenance Prevention
(MP) Design
©2008 Productivity Inc. All Rights Reserved
EEM and MP Design
EEM and MP Design are two methods of making improvements at the earliest possible stage, with the goal of “fix and repair” and defect free equipment.
In other words…Operator/Maintenance friendly equipment through lessons learned on existing equipment and applied to new equipment during the concept, design, and installation phase(s).
©2008 Productivity Inc. All Rights Reserved
EEM/MP Design Involvement
EEM/MP Design is a team approach. The team should ALWAYS include members from…
Maintenance (hourly)Production (hourly)Engineering/Technical
©2008 Productivity Inc. All Rights Reserved
Maintenance Process Improvement (MPI)
(Planned, Scheduled Maintenance System)
©2008 Productivity Inc. All Rights Reserved
MPI Tools and Activities
Well trained/skilled craftspeopleLubrication ManagementPreventive Maintenance systemPredictive TechnologiesDocumentation ManagementEEM/MP Design InvolvementMaintenance Management SystemSpare Parts Management
©2008 Productivity Inc. All Rights Reserved
The Maintenance Techniques
Preventive Maintenance – preventing breakdownsCorrective Maintenance – improving or modifying equipment to prevent breakdowns or to make maintenance easierMaintenance Prevention – designing and installing equipment that needs little or no maintenanceBreakdown Maintenance – repairing or fixing after breakdowns occur
©2008 Productivity Inc. All Rights Reserved
©2008 Productivity Inc. All Rights Reserved
©2008 Productivity Inc. All Rights Reserved
©2008 Productivity Inc. All Rights Reserved
Systematic Equipment Improvement
(Improve Equipment Effectiveness)
©2008 Productivity Inc. All Rights Reserved
SEI
A systematic approach to eliminate waste through analysis of the “6” major losses utilizing cross-functional teams to continuously investigate, test, and implement improvements with a goal of maximizing equipment effectiveness.
DATA DRIVEN PROCESS!!!
©2008 Productivity Inc. All Rights Reserved
Six Major Losses toEquipment Effectiveness
Failures
Setup/changeover and adjustments
Idling and minor stoppages
Reduced speed
Defects and rework
Startup loss
©2008 Productivity Inc. All Rights Reserved
How the Losses Reduce Effectiveness
QualityPerf.EfficiencyAvailability
OverallEquipment
Effectiveness= xx
ReducedSpeed
StartupLosses
Minor Stopsand Idling
Adjustmentsand Set-Ups
EquipmentFailures
Rejects andDefects
6 MajorLosses
©2008 Productivity Inc. All Rights Reserved
Autonomous Maintenance
©2008 Productivity Inc. All Rights Reserved
What IsAutonomous Maintenance?
A collaborative team activity involving production, maintenance, and engineeringAn approach that• develops operating and maintenance skills• strengthens communication and cooperation
A series of activities implemented in well-defined developmental steps
©2008 Productivity Inc. All Rights Reserved
Seven Steps ofAutonomous Maintenance
1. Conduct initial cleaning/inspection
2. Eliminate sources of contamination
3. Establish provisional standards
4. Develop general inspection training
5. Conduct general inspections
6. Improve workplace management and control
7. Participate in advanced improvement activities
©2008 Productivity Inc. All Rights Reserved
Cross-Functional Team Activity
©2008 Productivity Inc. All Rights Reserved
©2008 Productivity Inc. All Rights Reserved
©2008 Productivity Inc. All Rights Reserved
©2008 Productivity Inc. All Rights Reserved
©2008 Productivity Inc. All Rights Reserved
©2008 Productivity Inc. All Rights Reserved
©2008 Productivity Inc. All Rights Reserved
©2008 Productivity Inc. All Rights Reserved
©2008 Productivity Inc. All Rights Reserved
©2008 Productivity Inc. All Rights Reserved
©2008 Productivity Inc. All Rights Reserved
©2008 Productivity Inc. All Rights Reserved
Zero Breakdown Strategies
Restore equipmentMaintain basic equipment conditionsAdhere to standard operating proceduresImprove operator maintenance skillsDon’t stop at emergency fixesCorrect design weaknessesStudy breakdowns relentlessly
©2008 Productivity Inc. All Rights Reserved
“Button-pushers” to Process Owners
“Firefighters” to Maintainers