TPM

Total Productive Maintenance
(TPM)
TPM A Definition
Total Productive Maintenance

(TPM) is a manufacturing
initiative for optimizing the
effectiveness of equipment.
Why Do We Need TPM?
Cannot become Lean if we have defective or

interrupted supplies
Cannot have zero defects if the equipment does not
function properly
Cannot avoid supply interruptions, if we have
equipment breakdowns
Zero accidents and cleanliness are not possible if all
systems of the equipment do not function properly
TPM Goal of Zero Losses
Zero breakdowns
Zero defects
Zero losses due to wasted time
Zero accidents
Zero leaks
Common Reasons for

Losses
Lack of spare parts

Lack of maintenance scheduling
Lack of equipment availability
Lack of planning
Untrained craftsmen, operators, and management
Poor housekeeping
Equipment does not match the needs
Poor communication
No preventative maintenance programs
No sustained commitment (involvement)
Role of the Operators in TPM

Perform routine services, such as cleaning, lubricating,
and inspections.
Keep equipment in good operating condition by following
standard practices, visual inspections, etc.
Detect deterioration or abnormalities, including wear,
quality problems, etc., and get them fixed
Continue to acquire additional operational and
maintenance skills
Adjustments, Set-Up Reduction, etc.
Total Productive
Maintenance
Predictive
Preventive
Proactive
Introduction to OEE
What is OEE?
OEE stands for Overall Equipment

Effectiveness
OEE is a measurement that represents the
percentage
of time a machine was actually producing
quality parts compared to the time it was
planned to be
OEE provides a measure of equipments actual

productivity compared to the ideal productivity,
during a specified period
of time
The difference between actual and ideal is

waste, which must be eliminated
Missing
Information
Availability Goal
Performance Goal
Quality Goal
%
OEE Goal
Six Big Losses
Six Loss Categories

Idle Time Losses
Set-up Time Losses
Maintenance Time Losses
Miscellaneous Time Losses (All Others)
Quality Time Losses
Slow-down (Speed) Losses
Objectives of OEE
Measurement
Monitor critical equipment performance
Monitor TPM implementation
Better evaluate capital needs
Analyze the loss data to
Capture operators notes and actions.
Monitor autonomous maintenance
Monitor impact of set-up reduction efforts
What is Autonomous
Maintenance?
Similar words and phrases for autonomous
Self-governing
Independent
Self-ruling
Free
Non-centralized
A self-governing (by the operators) equipment

maintenance program
Seven Steps of Autonomous

Maintenance
1.
2.
3.
4.
5.
6.
7.
Perform initial cleaning & inspection

Eliminate causes of contamination & inaccessible areas
Develop cleaning, lubricating, and inspection standards
Provide basic training in machines function and controls
to enable effective general inspection
Enhance and implement autonomous inspection
standards & schedules
Implement workplace organization & housekeeping,
employing 5S & visual controls
Follow up on all the above steps and advanced
improvement activities

Maintenance

Maintenance
1.
2.
3.
4.
5.
6.
7.

Provide basic training in machines function and controls to
enable effective general inspection
Enhance and implement autonomous inspection standards
& schedules
Cleaning
Ensure that the machine is kept clean inside and

out
Develop low cost methods for preventing
lubricant contamination
Avoid using compressed air for cleaning
Devise innovative methods for flushing chips
and swarf and to prevent them from entering
between sliding surfaces
Inspections
Check belts, chains, couplings, conveyors

Check for loose or missing nuts, washers, bolts
Check for excessive vibration
Check for excessive noise
Check for excessive heat
Check for leaks
Check for dirty filters
Check for fluid levels
Check gages for pressures
Lubrication
Ensure that all lubrication reservoirs are filled to the

proper full mark
Check for excessive heating of lubrication
Insure lubricants are changed out in a timely manner
Implement oil sampling program
Ensure that all grease fittings are functional and are
being greased as per the schedule
Abnormalities to look for
Missing, broken or damaged parts

Wear of sliding surfaces
Play, looseness, sagging, excessive movements
Warped, deformed, misaligned
Rust & other surface damage
Leaks, splattering
Vibration, shaking
Unusual sounds, abnormal heating
Unusual smell & discoloration
Broom not stored
480 Volt Electrical cover blocked open
Grit & Grime
Cover on motor wiring box missing
Conduit pulled out of Connector
Missing Mounting Bolt - Abnormality
No Oil in
lubricator
Abnormality
Heavily
contaminated air
filter element
Cover loose - abnormality

Contaminated Hydraulic Motor Fan - Abnormality
Machine parts
lying around on
machine
Set Up parts
laying on machine
Gage broken and

full of water

Maintenance
1.
2.
3.
4.
5.
6.
7.

Eliminate causes of contamination & inaccessible
areas
Provide basic training in machines function and controls, to
& schedules
Eliminating Contamination
What contaminates?
Leaking or splattered fluids oil, water, coolant

Chips or swarf
Foreign matter dust, packing material, mist
Examples of improvements
Repair leaks, reduce overflows

Install shields / covers to contain cutting debris
Install dirt and debris collectors
Devise efficient washing methods
Reduce/control air flow
Some of the Causes of

Inaccessibility
Hidden locations
Behind the machine, behind covers

Obscured by other parts, hoses, pipes, cables
Moving parts have to be aligned in certain way
Difficult locations
Go through hazardous chips

Go through oily areas
Possibility of exposure to electric shock, high pressures,
high temperature
High up from the floor or too close to the floor

Maintenance
1.
2.
3.
4.
5.
6.
7.

Develop cleaning, lubricating, and inspection
standards
& schedules
Lubrication Standards Must

Specify
Lubrication points
Criteria for acceptance
Oil level within range
Film of oil on surface
Sufficient grease
Type of lubricant to use

Tools needed to apply lubricants
Barrel pump
Grease gun
Frequency for checking & lubrication

Responsible person for checking
Studer S20 CNC Universal

Cylindrical Grinder
Example Provisional Cleaning

Standard
5
1
9
6
2
3
4
8
7
Example
Provisional Lubrication & Inspection
Standard
D
5
4
A
H
C
G
E
TPM Operator Check List

Operator Checklist
K/T 180 GD-15 - GD-16

Operator
Daily
1. Clean both tool changers
2. Clean all the way covers
3. Clean all pallet stands
4. Check hyd. Tank fluid level
Weekly
1. Clean the Hyd. Tank & motor
2. Clean both Z-axis
3. Inspect machine for abnormalities
Monthly
1. Check hydraulic filters
Week ending
Mon
Tue
Wed
Thu
Fri
Sat
Sun
TPM PROVISIONAL CLEANING STANDARD

Machine: K&T Rotor Slot Mill
Date: May 1999
# Location
1 Complete
head and
column areas
2 Electrical
cabinet
Method
Criteria
Shft MON TUE WEDTHU FRI SATSUN
Spray bottle, Free of grime,
123 123 123 123 123 123 123
wipe with rag dry to touch
X
[][][] [][][] [][][] [][][] [][][] [][][] [][][]
Spray bottle, Free of grime,
wipe with rag dry to touch
X
123 123 123 123 123 123 123

[][][] [][][] [][][] [][][] [][][] [][][] [][][]
TPM PROVISIONAL CLEANING STANDARD

Machine: K&T Rotor Slot Mill
Date: May 1999
5
# Location
Method
3 Front spindle Spray bottle,
area
wipe with rag
4 Overarms and Spray bottle,
arbor support wipe with rag
5 Haas indexing Spray bottle,
fixture
wipe with rag
Criteria
Free of grime,
dry to touch
Free of grime,
dry to touch
Free of grime,
Spray with
WD-40
Shft MON
123
X
[][][]
123
X
[][][]
X
TUE
123
[][][]
123
[][][]
WED THU FRI

123 123 123
[][][] [][][] [][][]
123 123 123
[][][] [][][] [][][]
SAT
123
[][][]
123
[][][]
SUN
123
[][][]
123
[][][]
123 123 123 123 123 123 123

[][][] [][][] [][][] [][][] [][][] [][][] [][][]
Summary
Steps One, Two and Three
Step 1 Stabilize equipment condition
Step 2 Stop accelerated deterioration
Step 3 Maintaining basic equipment condition
Steps One, Two and Three

together constitute the beginning
phase of a TPM program for zero failures
Safety Rules for Team Members

It is the responsibility of each team member to use safe
practices at all times to avoid injury to themselves and to
fellow employees
Verify that equipment has been properly locked out, tagged
out before starting work
Verify that all stored energy has been released
Ensure that the air pressure is relieved from all air lines
and components
Ensure that the hydraulic pressure from all lines &
components is relieved
Electronic technicians should ensure that all capacitors
and circuits are discharged
continued
Safety Rules for Team Members

continuation
Appropriate safety glasses with side shields must

be worn at all time
Safety shoes must be used to prevent foot and toe
injuries
Lift the correct way and safe way
Bend your knees and keep your back straight
Use of hand tools
Use the correct tool for the job

Make sure the tools are in good condition
Use the tools in the correct manner
continued
Cleaning and Inspection Activities

Perform visual inspection noting all abnormalities
Clean by removing dirt and grime
Use all five senses to discover additional abnormalities
Record all abnormalities
Take pictures of abnormalities
Identify and record areas for improvements
Gather data for provisional standards

Maintenance
1.
2.
3.
4.
5.
6.
7.

Provide basic training in machines function and
controls to enable effective general inspection
& schedules
Guidelines for Training to

Sustain Step 4 Objectives
Training topics are selected based on the sites needs
TPM teams develop the training material
Training is provided one topic at a time
Implementation is reinforced through practice
Training material is regularly updated
Training should be repeated for reinforcement
Training Considerations
Who provides training?
Maintenance person
Team leader
Member of management
In-house training department
Other consultants, schools, community colleges,
on-line, correspondence
Self learning books, CDs, videos
Training Topics
Lubrication
Fasteners (Screws, Nuts, Bolts & Washers)
Pneumatics
Hydraulics
Electrical Systems
Drive Systems

Maintenance

5. Enhance and implement autonomous inspection
6. Implement workplace organization & housekeeping,
7. Follow up on all the above steps and advanced
1.
2.
3.
4.
Step 5 Activities
Review all tasks with maintenance to resolve any

inconsistencies between the maintenance department
and operators
Ensure that all equipment improvement activities have
been incorporated into the standards
Ensure that up-to-date standards are placed in all the
autonomous maintenance manual
Autonomous Maintenance
Audits
Objective of the audit should be
Ensure that all activities are being carried out

Verify that TPM teams are identifying and pursuing root
causes of breakdowns
Verify that visual controls are implemented
Verify operator proficiency in carrying out tasks
Ensure that the methodology is being followed correctly
Seven Steps of Autonomous Maintenance

1.
2.
3.
4.
5.
6.
7.

Enhance and implement autonomous inspection
Implement workplace organization &
housekeeping, employing 5S & visual controls
Visual Controls
Example Visual Control For

Machine Lubrication
Oil Drums
1
Oil Supply Cans With

Spigots
Lubrication Tools
Identified Lubrication
Points
Lean One Minute Lesson

Lubrication Visual Controls
Red
Red Grease Shell Retina LIZ 2

Substitute Aeroshell 22
Green
Shell 46 Hydraulic Oil
Blue
Texaco Regal R & O 220
Yellow
Shell 32 Lubricator
Visual Controls Developed for all

Lubrication Types
Color of Lubrication Tool

Matches Visual Control
Dept / Machine: All

Date Developed: March 2005
Visual Controls Marked at Lubrication Points on

Machine to Ensure Proper Lubrication
Developed By: ATS Team
Example Visual Control For Machine

Lubrication
Oil
Type
Mobil
#32
Daily
Hydraulic
Tank
Paint Lube
Type
Color Dot
Oil
Inlet
Hi Low Level
Marks
H
L
Mark Hi-Low
Points
Visual Control Examples G
Gages In One Place
Gages With Marked Limits
22#
35#
10#
Labeled Gages
Gages Oriented to Point UP
Gages With Alarms
Areas of Visual Control

Opportunities
Materials/ Process/ Object
Contents/quantity in storage and transport units

Quantity in production unit (lot size)
Date of process completion, product delivery
Production sequence - where last - where next
Process priority FIFO
Method, frequency and results of inspection
Designation of long - waiting material
Deadline and individual assigned to dispose of defective or long waiting material
Storage Space
Quantity of work in process

Maximum allowable in storage
Separate space for conforming and non-conforming material
Establish methods for placement and stacking
Means of regulating use (FIFO)
Equipment/ Safety
Schedule stop or breakdowns

Workload of major equipment for next period
Routine equipment maintenance procedure
Maintenance routing for tools, fixtures, measuring instruments
Routine measure for minor repairs parts and adjustments
Location of frequently used tools
Quality/ Productivity
Daily defect reports

Daily production output
Scrap results
Actual results compared to monthly schedule
Gauge marking film . . .
Zebra cards cut to

fit make the fluid
levels show up!
Fluorescent orange and

green cardstock tags
Plastic-protected
tag for harsh
conditions
Inspect equipment
and tag problems
Pin-points the actual

location
PROBLEM TAG
Date ___________ Shift _______
(part 1)
(NNNNN)
By ________________________
Problem: 4
o Operation
o Electrical
o Instrument/Control
o Mechanical
o Utility/Facility
o Lubrication
o Other__________
Brief Description of Problem:
PROBLEM TAG
Date ___________ Shift _______
11
(part 2)
(NNNNN)
Acts as a reminder
By ________________________
Use as a mini-work
request
Problem: 4
o Operation
o Electrical
o Instrument/Control
o Mechanical
o Utility/Facility
o Lubrication
o Other__________
Description of Problem: (continue on back)
Communicates to
others: Part 1 on the
equipment Part 2 in
the area
Possible Impact of Problem: 4

o Availability (Uptime)
o Waste
o Performance/Speed
o Cost
o Quality of Product
o ________
o Environmental
o Safety
Corrective Action Plan:
W/O # __________
By:___________________Date:__________
By:___________________Date:__________
By:___________________Date:__________
Location/System/Equipment/Part I.D.:
Root Cause/Action: (continue on back
Date Completed: _________ OK _________

1996 Strategic Work Systems, Inc.Mill Spring, NC 28756
<<My Documents\Visual Systems Book\Problem Tag.eps>>
22
Many uses for

industrial strength
paint pens . . .
Many uses for

industrial strength
paint pens . . .
Match marking
critical nuts and
bolts after proper
tightening . . .
Many uses for

industrial strength
paint pens . . .
Match marking
critical nuts and
bolts after proper
tightening . . .
Temperature labels
monitor 24 hours, 7
days, all year
Vibration analysis
pickup discs
Paint pens mark

acceptable ranges in green
on temperature labels
Seal critical nuts

and bolts to show
signs of tampering
or loosening.
Rotating targets for motors, fans and pumps in storage

prevents false brinelling of bearings
Glue or tape to ends of

shaft and rotate at
specified intervals
with color of the month at
12:00 oclock position
Seven Steps of Autonomous Maintenance

1.
2.
3.
4.
5.
6.
7.

& schedules
Objectives of Step 7
Strengthen & consolidate TPM teams throughout
the plant
Continue to standardize improvement activities
Implement results to all other equipment / areas
Make progress per the master plan
Continues to build operators diagnostic and
maintenance skills

TPM

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Total Productive Maintenance

Total Productive Maintenance

Why Do We Need TPM?

Cannot become Lean if we have defective or

TPM Goal of Zero Losses

Common Reasons for

Lack of spare parts

Role of the Operators in TPM

OEE stands for Overall Equipment

OEE provides a measure of equipments actual

The difference between actual and ideal is

Six Big Losses

Six Loss Categories

Similar words and phrases for autonomous

A self-governing (by the operators) equipment

Seven Steps of Autonomous

Perform initial cleaning & inspection

Seven Steps of Autonomous

Seven Steps of Autonomous

Perform initial cleaning & inspection

Ensure that the machine is kept clean inside and

Check belts, chains, couplings, conveyors

Ensure that all lubrication reservoirs are filled to the

Abnormalities to look for

Missing, broken or damaged parts

Broom not stored

480 Volt Electrical cover blocked open

Grit & Grime

Cover on motor wiring box missing

Conduit pulled out of Connector

Missing Mounting Bolt - Abnormality

Cover loose - abnormality

Gage broken and

Seven Steps of Autonomous

Perform initial cleaning & inspection

Leaking or splattered fluids oil, water, coolant

Repair leaks, reduce overflows

Some of the Causes of

Behind the machine, behind covers

Go through hazardous chips

Seven Steps of Autonomous

Perform initial cleaning & inspection

Lubrication Standards Must

Oil level within range

Film of oil on surface

Type of lubricant to use

Frequency for checking & lubrication

Studer S20 CNC Universal

Example Provisional Cleaning

TPM Operator Check List

K/T 180 GD-15 - GD-16

TPM PROVISIONAL CLEANING STANDARD

Date: May 1999

123 123 123 123 123 123 123

TPM PROVISIONAL CLEANING STANDARD

Date: May 1999

WED THU FRI

123 123 123 123 123 123 123

Steps One, Two and Three

Safety Rules for Team Members

Safety Rules for Team Members

Appropriate safety glasses with side shields must

Bend your knees and keep your back straight

Use of hand tools

Date Completed: _ OK _