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TOTAL PRODUCTIVE MAINTENANCE

TOTAL PRODUCTIVE MAINTENANCE. ‘Failure prevention’. LEARNING OUTCOMES. …to understand the concept of Total Productive Maintenance (TPM) …to understand the impact of failure for a fashion operation. DEFINITION OF TPM.

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TOTAL PRODUCTIVE MAINTENANCE

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  1. TOTAL PRODUCTIVE MAINTENANCE ‘Failure prevention’

  2. LEARNING OUTCOMES …to understand the concept of Total Productive Maintenance (TPM) …to understand the impact of failure for a fashion operation

  3. DEFINITION OF TPM “Total Productive Maintenance recognises the importance of reliability, maintenance and economic efficiencyin plant design” “Accepting that sometimes failure will occur is not the same as ignoring it” (Slack et al, 2007)

  4. THE FIVE GOALS OF TPM • Improve equipment effectiveness • Achieve autonomous maintenance • Plan maintenance • Train all staff in relevant maintenance skills • Achieve early equipment management

  5. THE GOAL OF TPM • To minimise waste in a fast changing economical environment • To increase production efficiency without reducing product quality • To reduce cost • To reduce production time • To ensure non defective goods to customer

  6. The facts - what has happened? Discover The consequences Inform, contain and follow up Act Find the root cause Learn Prevent it happening again Failure analysis - possibilities Plan Recovery planning - procedures FAILURE PLANNING

  7. Failures inside the operation Supply failures Customer failures Design failures Facilities failures Staff failures TYPES OF FAILURE Environmental disruption

  8. FAILURE DETECTION • In-process checks • Machine-diagnostic checks • Point-of-departure interviews • Accident investigation • Product liability • Complaint analysis • Critical incident analysis • Failure mode-and-effect analysis • Fault-tree analysis FAILURE ANALYSIS

  9. FAILURE MEASUREMENTS • Failure Rate (FR) • Reliability • Availability

  10. Failure detection and analysis Finding out what is going wrong and why Improving system reliability Recovery Stopping things from going wrong Coping when things do go wrong FAILURE ANALYSIS AND RECOVERY PLANNING

  11. BENEFITS WITH TPM • Improved system reliability • Increases productivity (by 1.5 to 2 times) • Resolves customer complaints • Reduces manufacturing cost (by 30%) • Satisfy customer needs (by 100%) • Right quantity, time, quality • Reduce accidents • Follow pollution and control measures

  12. TPM vs. TQM SIMILARITIES • Total commitment • Employee empowerment • A holistic approach to improvement DIFFERENCES

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