Chapter 6
Total Productive Maintenance
(TPM)
Total Productive Maintenance
Outcomes
– Understand the basics of total productive
maintenance (TPM)
– Learn the prerequisites of TPM
– Learn the main components of TPM
– Understand autonomous maintenance and
preventative maintenance
– Learn what is involved in a TPM
implementation plan
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What is TPM
• It is a method for continuously improving
the effectiveness of production equipment
or manufacturing processes through the
involvement of all people in the
organization
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Definition
TPM – A company wide, team-based effort to improve output quality through
equipment care and to improve overall equipment effectiveness
Total
• All employees are involved
• Aims to eliminate all accidents, defects, and breakdowns
Productive
• Actions performed during production
• Troubles for production are minimized
Maintenance
• Keep in good condition
• Improve Overall Equipment Effectiveness (OEE)
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Customer Satisfaction
• The goal of TPM is to maintain equipment
so it will be able to achieve 100% ondemand availability for immediate use by
the next process or customer.
– Equipment breakdowns, unplanned downtime
– Scrap/rework
– Reduced productivity
– Equipment start-up losses
– Set-up time
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TPM Origins
• Actually started here in the U.S.
• American manufacturing’s neglected asset
TPM Rule #1:
• Issues relating to job security,
responsibilities, classifications, and union
support must be resolved.
TPM Rule #2:
• Success depends on daily activities,
culture.
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TPM Goal
• Maximize Overall Equipment Effectiveness
by minimizing equipment-related losses.
• Provide a system of comprehensive
maintenance for the life cycle of
equipment.
• Involve departments that plan, design,
use, and maintain the equipment.
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Reactive vs. Proactive
• Reactive
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–
–
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Putting out fires
Getting it out the door
Customer “needed it yesterday”
Building it “just in case”
• Total Productive Maintenance is Proactive
– Preventative maintenance – maintain to prevent
breakdowns
– Predictive maintenance – schedule maintenance
based on Mean Time To Failure (MTTF)
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5 TPM Principles
1. Improve Overall Equipment Effectiveness
(OEE)
2. Improve operators in daily maintenance
3. Improve maintenance efficiency and
effectiveness
4. Train all personnel
5. Establish early equipment management and
maintenance prevention programs
TPM Prerequisites
1. Must be measuring OEE
2. 5S workplace organization
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Main Components of TPM
Autonomous maintenance – operators take
ownership of equipment and conduct
regular cleaning, lubricating and minor
maintenance themselves.
Strengthened preventive maintenance
system – includes scheduled, predictive
and condition-based maintenance
programs.
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TPM Results
• Improved quality
• Improved productivity
• Improved delivery
• Reduced inventory
• Improved team member job satisfaction
TPM Rule #3:
• A partnership must be developed between mfg,
maintenance, & eng. which fosters an
atmosphere of eqpt ownership.
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TPM Rule #4
• The key to an effective PM component
within the TPM initiative is the machine
operators.
• Up to 75% of breakdowns can be detected
and prevented by well trained operators.
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Implementation Prerequisites
•
•
•
•
Top management commitment
5S implementation and team building
Dedicated people (Project Champions)
Flexible, cross-trainable workers.
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Maintenance Strategies
•
•
•
•
•
Breakdown
Preventative
Predictive
Corrective or Improvement
Maintenance Prevention
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Autonomous Maintenance
7 Steps to Establish an Autonomous Maintenance System
1.
2.
3.
4.
5.
6.
7.
Initial cleaning
Address the causes and spread of contamination
Develop cleaning, lubrication and bolt
tightening/inspection standards
General inspection training
Autonomous maintenance
Workplace organization standards
Full implementation of autonomous maintenance
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Preventative Maintenance/Maintenance
Prevention
• Reason for Preventative Maintenance
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–
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Improve OEE by reducing downtime
Extend Equipment life – protect investment
Increased reliability reduces inventory for JIT
Reduced energy/consumable cost
Reduced spare parts inventory
• Maintenance Prevention
– Design to prevent need for maintenance
– 95% of equipment’s Life Cycle cost is determined in
the design phase
– Requires teamwork of design engineers, maintenance
technicians and operators.
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Improvement Measurements
• Equipment breakdowns
• Scrap/rework
• Reduced productivity
• Equipment start-up losses
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Overall Equipment Effectiveness
OEE is the product of the three
measurements below.
• Equipment Availability
– Measures how often eqpt is not producing
• Equipment Efficiency Performance
– Measures actual machine cycle time
• Equipment Quality Performance
– Compares the # of good pieces
produced/total number produced
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Equipment Availability (EA)
EA = Scheduled Production Time - Unplanned Downtime
Scheduled Production Time
Since, Uptime = Scheduled Production Time – Unplanned Downtime
Then, EA = Uptime
Scheduled Production Time
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Equipment Efficiency Performance
(EEP)
EEP = (Standard Cycle Time) X (# of pcs Produced)
Uptime
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Equipment Quality Performance
(EQP)
EQP = Total # Produced – Total # Defective
Total # Produced
Since, # of good pieces = Total # Produced – Total # Defective
Then, EQP = # of Good Pieces
Total # Produced
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Overall Equipment Effectiveness
(OEE)
OEE = (EA) X (EEP) X (EQP)
Current World Class benchmarks for these
are:
EA = 90%, EEP = 95%, EQP = 99%
OEE = 85%
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Summary
• TPM can significantly improve a plant’s
quality, productivity, and product delivery
• TPM can generate culture changes in a
plant.
• The only long term competitive advantage
any company can have is its people.
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Conclusion
TPM implementation depends on condition of
equipment, work culture, equipment
management, and maintenance effectiveness.
• TPM Benefits
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Reduced equipment downtime
Increased equipment productivity
Increased plant capacity
Lower maintenance and production costs
Approaching zero equipment caused defects
Enhanced job satisfaction
Increased Return-on-investment
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