Total Productive Maintenance

TPM

AGENDA

TPM

Agenda

» Introduction To TPM» Why – Benefits?» Typical Maintenance Strategies» What Does TPM Look Like?» How to Start Using TPM» Sustaining» Summary / Questions

AGENDA

TPM

INTRODUCTION

TPM

What is TPM?

» TPM is a method for continuously improving the effectiveness of production equipment and processes

Introduction

TPM

» By improving On Demand availability of the equipment, through improved maintenance

How is this Accomplished?

How is this Different from Other Maintenance Programs?

» Primary difference between TPM and most maintenance programs is the involvement of the machine operator as a front line defense against…

Introduction

TPM

– Equipment breakdowns and other unplanned downtime

– Scrap and rework caused by poor equipment performance

– Reduced productivity due to running at reduced speeds, idling, or stoppages requiring operator attention

– Equipment startup losses

Brief History of TPM

» Preventative maintenance originated in the United States in 1940’s

Introduction

TPM

» Japanese auto manufacturers studied these methods in the 1950’s

» First true TPM initiative developed by Nippondenso in the late 1960’s

» First true TPM in the United States developed by Kodak’s Tennessee Eastman facility in 1987

Why is TPM Important?

TPM

Why is TPM Important

TPM

Why is TPM Important

TPM

WHY???

» Maximizes the productivity of equipment for its entire life cycle

Why is TPM Important – Benefits

TPM

» Extends equipment life

» Increases the amount of time equipment can be doing what we need it to do

» Builds / Trains a workforce that can most effectively help the organization best utilize it’s equipment

WHY??? To reduce Waste?

» Equipment Breakdowns

Why is TPM Important – Benefits

TPM

» Setup and Adjustment Delays

» Idling and minor stoppages

» Reduced Speed

» Process Defects

» Reduced Yield

Typical Maintenance Strategies

TPM

Types

Typical Maintenance Strategies

TPM

» Reactive» Preventive» Predictive» Corrective Maintenance» Maintenance Elimination

» All of these can have a place, yet some better than others

Most Common Strategy?

Typical Maintenance Strategies

TPM

“If it ain’t broke, don’t fix it”.

» Reactive Maintenance

Reactive Maintenance = 55%

Typical Maintenance Strategies

TPM

» Advantages• Low cost• Less staff

» Disadvantages• Increased cost due to unplanned

downtime of equipment • Increased labor cost, especially if

overtime is needed ,cost involved with repair or replacement of equipment.

• Possible secondary equipment or process damage from equipment failure.

• Inefficient use of staff resources.

Can we get better?

Typical Maintenance Strategies

TPM

» Preventive Maintenance

Time or Machine cycle based maintenance functions

Preventive Maintenance = 31%

Typical Maintenance Strategies

TPM

» Developed by US Navy» Advantages• Cost effective in many capital-intensive processes• Flexibility allows for the adjustment of maintenance schedules• Increased component life cycle• Energy savings• Reduced equipment or process failure• Estimated 12% to 18% cost savings over reactive maintenance

program.

» Disadvantages • • Catastrophic failures still likely to occur• Labor intensive• Includes performance of unneeded maintenance• Potential for incidental damage to components in conducting unneeded

maintenance.

Anything Better?

Typical Maintenance Strategies

TPM

» Predictive Maintenance

Maintenance functions based on feedback, predicting that something needs to be done.

Predictive Maintenance = 12%

Typical Maintenance Strategies

TPM

» Advantages• Increased component operational life/availability.• Allows for preemptive corrective actions.• Decrease in equipment or process downtime.• Decrease in costs for parts and labor.• Better product quality.• Improved worker and environmental safety.• Improved worker morale.• Energy savings.• Estimated 8% to 12% cost savings over preventive

maintenance program.

» Disadvantages• Increased investment in diagnostic equipment.• Increased investment in staff training.• Savings potential not readily seen by management.

More?

Typical Maintenance Strategies

TPM

» Corrective Maintenance

Modifying a piece of equipment such that it will last longer.

More?

Typical Maintenance Strategies

TPM

» Maintenance Elimination

Removing or reducing the need for maintenance to occur

What Does TPM Look Like?

TPM

TPM Implemented?

What Does TPM Look Like?

TPM

» Machine Operators are trained to do much of the maintenance operations, and it’s part of their Standard Work

TPM Implemented?

What Does TPM Look Like?

TPM

» Tools necessary are readily available

TPM Implemented?

What Does TPM Look Like?

TPM

» Equipment modified such that easy to keep clean, easy to see when maintenance is required.

Before

After

TPM Implemented?

What Does TPM Look Like?

TPM

» More examples of easily cleaned and seen

Before

After

Filtered Air

TPM Implemented?

What Does TPM Look Like?

TPM

» More examples of easily cleaned and seen

Before

After

TPM Implemented?

What Does TPM Look Like?

TPM

» Equipment modified such that easy to maintain

How to Implement?

TPM

How To….

How To Implement?

TPM

1. Select Equipment to work on

2. Begin with 5Sing, Initial Clean Up

3. Define Machine Operator Maintenance Tasks• Modify equipment to facilitate tasks

4. Define Maintenance Technician Tasks• Provide “informative” tools to assist

5. Sustain

How To….

How To Implement? | Equipment Selection

TPM

1. Select Equipment to work on….• Equipment that is giving you problems with…

• Unplanned downtime• Excessive quality problems• Excessive repair costs• Premature “end of life” failures• Running slower than “design” to prevent

breakdowns

How To….

How To Implement? | Equipment Selection

TPM

2. 5S Event….• Improves ability to perform regular inspections• Allows the discovery of potential problems• Log problems and potential problems and develop

an immediate action plan• Mark all lubrication, fluid connections and

directions, etc• Paint equipment

How To….

How To Implement? | Equipment Selection

TPM

3. Defining Machine Operator Tasks• Develop Standards and Checklists

• Cleaning• Lubrication• Visual Checks• Procedures to keep equipment “as new”

How To….

How To Implement? | Equipment Selection

TPM

3. Make Machine Operator maintenance tasks easier/quicker• Easy to see when things need to be

maintained• Lubrication needs become obvious to operator• Routine cleaning operations easier• Machine disassembly minimized• Automate maintenance when possible• Clear signals when maintenance is needed

How To….

How To Implement? | Equipment Selection

TPM

3. Defining Machine Operator Tasks (cont.)• Train Operators on….

• Visual checks• Hydraulics• Electrical / electronics• Mechanical drive systems• Complex lubrication• Safety• Procedures for minor repair and

replacement• Criteria delineating operator and technician

approved activities

How To….

How To Implement? | Equipment Selection

TPM

3. Defining Machine Operator Tasks (cont.)• Implement Daily Operator Activities

• Review checklists with operators• Ensure operator training is complete• Finalize checklist schedules

How To….

How To Implement? | Equipment Selection

TPM

4. Define Maintenance Tech Tasks (Reactive) • Provide Tech support to operator questions• Provide clear communication path• Spare Parts Program

• Equip Manufacturer recommendations• Breakdown History Data• Kanban

How To….

How To Implement? | Equipment Selection

TPM

4. Define Maintenance Tech Tasks (Preventive) • Eliminate Equipment Deterioration

• Scheduled general inspections• Equipment overhauls• Triggered by checklists

• Identify and Resolve Chronic Problems• Breakdown history log• Root cause analysis methods• 5 Why analysis

How To….

How To Implement? | Equipment Selection

TPM

4. Define Maintenance Tech Tasks (Predictive) • Develop and Analyze Equipment History

• Plot failure history• Correlate with Equipment Quality

Performance• Determine Equipment Parameters That Predict

Failure• Use information from equipment

manufacturer• Oil, vibration, temperature analysis

• Develop Equipment Monitoring Systems• Ensure appropriate accuracy and tolerance• Lease equipment to ensure usability before

purchase

Sustain

TPM

Sustaining….

Sustain

TPM

» Measuring progress / status is key to sustaining

» Primary Measurement tool is OEE

» OEE – Overall Equipment Effectiveness, is measured….

OEE = Equip Availability X Performance Efficiency X Quality Rate

» Audit machine operator’s standard work» Audit maint tech’s standard work

Summary

TPM

» TPM is a method for continuously improving the effectiveness of production equipment and processes

Summary

TPM

» By improving On Demand availability of the equipment, through improved maintenance

» With a primary focus on involving machine operators in routine maintenance

» And making that maintenance easily seen, easily done, and effective

Q&A

TPM