Total Productive Maintenance

1. Total Productive Maintenance

2. TPM Training Agenda • TPM – History, benefits and typical results • Definition and “5 Pillars” of TPM • The “6 Big Losses” • Autonomous Maintenance • Maintenance Prevention • Setting Standards & Sustaining the Benefits • TPM and Safety • The Advisory Team • Equipment Improvement Teams (EIT’s) • TPM vs. 5S • Summary of TPM topics

3. Origins of TPM • Breakdown maintenance (RTF) - historical • Preventive Maintenance concept – introduced in1951 • Productive Maintenance introduced later • Included • Preventive maintenance • Improvement-related maintenance • Maintenance prevention • Still primarily maintenance department • Never achieved zero breakdowns or defects

4. Origins of TPM • Total Productive Maintenance • Brought operators into the picture • Small group activities • Teamwork between operators and maintenance • Involvement & support throughout the company

5. No Tolerance for Breakdowns • Equipment breakdowns impact • Customer service • Production costs • Maintenance costs • Effectiveness of “manufacturing cells” or “flow lines” • Breakdowns result in “chaos”

6. The Last 50 Years • In the 1950’s, about 70% of durable goods sold in the world were made in the U.S. …today << 10% • In the 1950’s, there were over 25 U.S. television manufacturers …by the early 1990’s, only 1 (Zenith) …today?? • In the 1950’s, the largest growing job was in manufacturing…not the case today!! Most manufacturing industries are fighting a war to survive!

7. 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 viability

8. 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

9. Typical TPM Results • Overall equipment effectiveness up 25-65% • Quality defects down 25-50% • Maintenance expenditures down 10-50% • Percent planned vs. unplanned maintenance increased 10-60%

10. 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. • TPM will not be an overnight success. Implementing it throughout a plant correctly will take several years.

11. Shift in Attitudes Maintenance Operator Maintenance Operator I maintain & I fix I use We maintain Conventional TPM

12. 5 Pillars of TPM • Improvement activities designed to increase equipment effectiveness (OEE) • Autonomous maintenance program performed by equipment operators • A planned maintenance system • Training to improve operation & maintenance skills • Effective new equipment design and startup

13. TPM Emphasizes Prevention Three Principles of Prevention • Maintain normal conditions • Early discovery of abnormalities • Operator • Maintenance • Prompt response

14. The Six Big Equipment Losses • Breakdowns • Setups and adjustment • Idling and minor stoppages • Speed • Quality defects and rework • Start-up (loss of yield)

15. Overall equipment effectiveness = Availability x Performance rate x Quality rate (OEE) Breakdown Setup and adjustment Others Quality defects & rework Start-up yield Idling & minor stoppages Reduced speed

16. Operation time (Scheduled time available – Downtime) Availability = ______________________________________________ x 100 Scheduled time available processed amount x ideal cycle time Performance rate = _____________________________ Operation time Quality rate = Amount good / amount produced

17. Improving OEE • Measure the extent of the 6 big losses • Analyze the causes (but focus your efforts ) • Develop solutions & create an improvement plan • Set targets and estimate the benefits to OEE • Carry out the plan • Establish measurements to monitor results • Repeat as necessary

18. 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

19. Eliminating Breakdowns Why machines fail • Disregard for basic needs (housekeeping, lube..) • Incorrect operating conditions • Lack of skill or knowledge of operator • Machine deterioration • Routine • Accelerated • Design deficiency

20. Eliminating Breakdowns • 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)

21. Autonomous Maintenance The principal way production workers participate in TPM Purpose • Brings production & maintenance people together to slow routine deterioration and halt accelerated deterioration • Helps operators learn more about their equipment (the cause and effect) • Prepares operators to be active partners with maintenance and engineering in improving equipment performance and reliability

22. Steps to Implementing Autonomous Maintenance Step 1: Initial cleaning and inspection Step 2: Eliminate sources of contamination and inaccessible areas Step 3: Develop and test cleaning, inspection, and lubrication standards Step 4: General inspection training and inspection procedures Step 5: Conduct autonomous general inspections

23. Steps to Implementing Autonomous Maintenance Step 6: Organize and manage the workplace Step 7: Ongoing autonomous maintenance and continued improvement

24. An advanced Improvement method • Maintenance Prevention Design-stage activities aimed at making new equipment reliable, easy to care for, and user friendly

25. Sustaining TPM • Audits • Visual activity boards • Team charter • Team activities, goal, schedule, and progress • Cleaning, inspection, and lubrication standards • Workplace organization standards • Trend charts for each of the big 6 losses • Inspection reports • Audit results • Before and after photos

26. 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

27. EIT EIT EIT EIT EIT EIT Setting Up a TPM Structure TPM Advisory Team Mgmt

28. 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 • Serve on EIT’s

29. 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

30. Setting Goals for Your TPM Program • Short term – 12 months • Establish an autonomous maintenance program for “x” machines • Increase OEE by “y”% within for individual work centers • Long term – Reach a plant OEE of 85% within 3 years (world class is considered about 85%)

31. Comparing TPM to 5S • 5S emphasizes • Productivity of workers • Organizing and visual indicators • TPM emphasizes • Effectiveness of equipment • Partnership between maintenance & production • Reducing lifetime equipment costs • Both emphasize • Initial cleaning and repair • Safety

32. FROM THIS to Planned repair PM Breakdown Shift in Equipment Maintenance Activities THIS Breakdown Predictive Planned repair PM Autonomous

33. Review of TPM’s 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

34. Review of TPM’s 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