Partners for Creative Solutions, Inc.

36 Deerfield Rd, Shrewsbury, MA 01545

508 845-1546 tmcbride@pcs-info.com

Total Productive Maintenance

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 Partners for Creative Solutions, Inc.

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 (EITs)
TPM vs. 5S
Summary of TPM topics

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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

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

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No Tolerance for Breakdowns

Equipment breakdowns impact

Customer service
Production costs
Maintenance costs
Effectiveness of manufacturing cells or flow
lines
Breakdowns result in chaos

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The Last 50 Years

In the 1950s, about 70% of durable goods sold in

the world were made in the U.S. today << 10%
In the 1950s, there were over 25 U.S. television
manufacturers by the early 1990s, only 1
(Zenith) today??
In the 1950s, the largest growing job was in
manufacturingnot the case today!!
Most manufacturing industries are fighting a war
to survive!
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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
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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

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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%

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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.

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Shift in Attitudes

Operator Maintenance Operator Maintenance

I use I maintain & We maintain

I fix

Conventional TPM
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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

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TPM Emphasizes Prevention

Three Principles of Prevention

1. Maintain normal conditions
2. Early discovery of abnormalities
a) Operator
b) Maintenance
3. Prompt response

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The Six Big Equipment Losses

1. Breakdowns
2. Setups and adjustment
3. Idling and minor stoppages
4. Speed
5. Quality defects and rework
6. Start-up (loss of yield)

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

Breakdown
Setup and adjustment
Others Idling & minor stoppages Quality defects & rework
Reduced speed 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

Quality rate = Amount good / amount produced

 Partners for Creative Solutions, Inc.

Improving OEE

1. Measure the extent of the 6 big losses

2. Analyze the causes (but focus your efforts )
3. Develop solutions & create an improvement plan
4. Set targets and estimate the benefits to OEE
5. Carry out the plan
6. Establish measurements to monitor results
7. Repeat as necessary
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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

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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

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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)

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Autonomous Maintenance

The principal way production workers participate in

TPM
Purpose
1. Brings production & maintenance people together to
slow routine deterioration and halt accelerated
deterioration
2. Helps operators learn more about their equipment
(the cause and effect)
3. Prepares operators to be active partners with
maintenance and engineering in improving equipment
performance and reliability

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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

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Steps to Implementing Autonomous

Maintenance
Step 6: Organize and manage the workplace
Step 7: Ongoing autonomous maintenance and
continued improvement

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An advanced Improvement method

Maintenance Prevention
Design-stage activities aimed at making new equipment
reliable, easy to care for, and user friendly

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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

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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

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 Partners for Creative Solutions, Inc.

Setting Up a TPM Structure

EIT
EIT EIT
TPM
Advisory Mgmt
Team
EIT EIT

EIT
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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 EITs

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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

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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%)

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Comparing TPM to 5S

5S emphasizes
Productivityof 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

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Shift in Equipment Maintenance

Activities

FROM THIS
to
THIS
Breakdown
Predictive
Planned repair Planned repair
PM PM
Breakdown Autonomous

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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

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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

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