TOTAL PRODUCTIVE

MAINTENANCE
OBJECTIVES
1. To understand the concept of TPM
2. To learn the importance of TPM
WHAT IS TPM?
Total Productive Maintenance
. A methodology aimed to forming a
corporate culture focused on maximizing the
efficiency of overall production system namely;
people and equipment

Focused on:
Improving skills at all levels
Optimizing equipment efficiency
Reducing Waste
TOTAL MEANS
Total efficiency
People (competency) + Equipment (Capability) = Company (Capacity)

Total Maintenance
TPM is a management Methodology which involves a defined concept for
maintaining plant and equipment.

Total Participation
Coordinating all department including those that design, maintain and
use equipment.
Involving everyone, from top executives to shop floor employees
Managing through Small Group Activities(SGA) aimed at plant wide
goals of zero losses.
INTRODUCTION
WHY DO WE NEED TPM?
Deal with loss and waste before it becomes a
problem
Make the best use of equipment performance
Maximize employees skills towards 4Zs
Survival in the next millennium
Restoration of basic equipment condition
Customer satisfaction

GOALS OF TPM
Zero Breakdown

Zero Defect

Zero Accident

Zero Waste/Loss
OBJECTIVES OF TPM
To improve equipment effectiveness
To achieve autonomous maintenance
To train staff in relevant maintenance skills
To plan maintenance
To achieve early equipment maintenance
I will use it until it breaks
You will fix it
I will fix it when it is down

I will design/ purchase a machine/
process that works

I will solve problem when they occur

I will direct the activities
Cluttered
Dangerous
Demanding
We will operate it efficiently
We will take care of it
We will prevent it from breaking
down
We will design/ purchase a
maintenance free machine/
process
We will support and prevent
problem from occurring
We will work together to optimize
the system
Clean
Safe
Enriching
Traditional TPM
Operators:

Technicians:

Engineers:

Supervisors:

Managers:

Factory Image:
TPM is the commitment of the total organization to preserve, Improve and maintain the
productivity and capacity of the company culture change..
EVOLUTION OF MAINTENANCE

TYPES OF MAINTENANCE
TYPES OF MAINTENANCE
TYPES OF MAINTENANCE
TYPES OF MAINTENANCE
TQM AND TPM
Category TQM TPM
Objects Quality (Output &
effects
Equipment (Input &
cause)
Means of attaining
goals
Systematize the
management. It is
software oriented
Employeesparticipatio
n.
Target Quality for PPM Elimination of losses
and wastes
PILLARS OF TPM
1. AUTONOMOUS MAINTENANCE PILLAR
(AM)
Who are involved?
Production Department

Aims:
Equipment Restoration
Empower and up skill operators
2. TRAINING & EDUCATION PILLAR
Who are Involved?
Training Department

Aims:
Support TPM Skills needs
Up skill operator and artisans
in technical ability
Assess gaps and train
3. PLANNED MAINTENANCE
Who are Involved:
Engineering
Production Department

Aims:
Eliminate Equipment Failures
Conduct Breakdown Analysis
4. ENVIRONMENT, HEALTH & SAFETY
PILLAR
Who are Involved:
EHS Department

Aims:
Eliminate Plant Risks
Align TPM to EHS Requirements
Improve operators

5. ADMIN/ SUPPORT PILLAR
Who are Involved:
Administrative and Support Department

Aims:
Implement TPM in offices
Conduct Kaizen in non production areas
Implement TPM in stores and logistics
6. QUALITY MANAGEMENT PILLAR (QM)
Who are Involved:
Quality Department

Aims:
Assess quality losses linked to equipment
Empower operators to control quality results through
Inspection
7. EARLY EQUIPMENT MAINTENANCE
PILLAR
Who are Involved:
Project & Maintenance Engineering

Aims:
Develop Learning Culture from previous
improvements
Include operators in designs.
Measure new equipment ramp up
8. FOCUSED IMPROVEMENT PILLAR
Who are Involved:
Project Teams (Engineering, Maintenance,
Production & Specialized Staff)

Aims:
Measure OEE and structure 16 Big Losses
Evaluate Loss Analysis and Kaizen Teams
AUTONOMOUS MAINTENANCE
Definition:
Autonomous means independent

Refers to activities designed to involve operators in
maintaining their own equipment.
AUTONOMOUS MAINTENANCE (JISHU HOZEN)
Objectives:
To prevent equipment deterioration through correct
operation and daily checks
To bring equipment back to its ideal state through
restoration and proper management
To establish the basic conditions needed to keep
equipment well-maintained.
To use the equipment as a means of teaching people
new ways of thinking and working.
AM IMPLEMENTATION STEPS
Step 0: Preparation
Step 1: Initial Cleaning
Step 2: Countermeasure of the sources of contamination
and hard to clean areas
Step 3: Cleaning Inspection and Lubrication Standards
Step 4: General Equipment Inspection development
Step 5: General Process Inspection set-up,
adjustment, Changeover
Step 6: Inspect for Quality in the workplace
Step 7: Full Autonomous Workforce
1
2
3
4
5
6
7
Countermeasures for Contamination
Initial Standards
General Inspection
Autonomous Inspection
Standardization
Aut. Mgt. 7
6
5
4
3
2
1
Initial Clean-up
HOW PEOPLE CAUSE MACHINE FAILURES?
We ignore about the sources of dirt in their
workplace.
We pay no attention to breakdowns and defects
as their own problems.
We cannot recover minor errors and cannot
execute minor repairs.
We dont have the knowledge of their basic
equipment check.
OPERATORS SKILLS
Ability to discover
abnormalities
Ability to correct
abnormalities and restore
functioning
Ability to set optimal
equipment condition
Learn simple disassembly
and repair procedures
Recognize deterioration
and improving equipment
to prevent it
Understanding Equipment
structure and Function
Understanding the causes
of Quality Defects
Knowledge of how to
conduct Minor Repairs
Equipment-Related Skills
Operator Knowledge
Level
STEPS IN INTRODUCTION OF TPM IN AN
ORGANIZATION
ORGANIZATION STRUCTURE FOR TPM IMPLEMENTATION
OEE
(OVERALL EQUIPMENT EFFECTIVENESS)
is a "best practices" way to monitor and improve
the effectiveness of your manufacturing processes
(i.e. machines, manufacturing cells, assembly
lines).
frequently used as a key metric in TPM
gives a consistent way to measure the
effectiveness of TPM providing an overall
framework for measuring production efficiency.
THE SIX BIG LOSSES
EQUIPMENT FAILURE OR BREAKDOWN
Sudden and unexpected equipment failures, or
breakdowns, are an obvious cause of loss, since
an equipment failure means that the machine is
not producing any output.

Tooling Failures
General Breakdowns
Unplanned Maintenance
SET-UP AND ADJUSTMENTS
Most machine changeovers require some period
of shutdown so that internal tools can be
exchanged.
The time between the end of production of the
last good part and the end of production of the
next good part is downtime. This downtime loss
often includes substantial time spent making
adjustments until the machine gives acceptable
quality on the new part.

Set-up/Change over
Warm up time

SPEED LOSSES
A speed loss means that the equipment is
running, but it is not running at its maximum
designed speed.

Types:
idling and minor stoppages
reduced speed operation.
SMALL STOPS
When a machine is not running smoothly and at
a stable speed
Typically includes stops that are under 5 minutes
and do not require maintenance personnel.

Obstructed product flow
Component jams
Misfeed
Sensor blocked

REDUCED SPEED
refers to the difference between the actual
operating speed and the equipments designed
speed (nameplate capacity).

Rough running
Equipment wear
Operator inefficiency

DEFECT LOSSES
A defect loss means that the equipment is
producing products that do not fully meet the
specified quality characteristics.

Types:
Scrap and rework
occurs when products do not meet quality specifications,
even if they can be reworked to correct the problem.

Startup losses.
occur when production is not immediately stable at
equipment startup, so the first products do not meet
specifications.
OEE CALCULATION
Loading Time
Operating Time
D
o
w
n
t
i
m
e

L
o
s
s

Net
Operating
Time
P
e
r
f
o
r
m
a
n
c
e

L
o
s
s

Value
adding
time
Q
u
a
l
i
t
y

L
o
s
s

Equipment 6 Big Losses
Breakdown
Set-up &
Adjustment
Small Stops
Reduced
Speed
Defects
Calculating OEE
OEE
OEE = Availability x Performance Rate x Quality Rate
= 87% x 50% x 98%
= 42 .63%

WORLD CLASS OEE