Total Productive
Maintenance
TPM
AGENDA
TPM
AGENDA
Agenda
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Introduction To TPM
Why – Benefits?
Typical Maintenance Strategies
What Does TPM Look Like?
How to Start Using TPM
Sustaining
Summary / Questions
TPM
INTRODUCTION
TPM
Introduction
What is TPM?
» TPM is a method for continuously
improving the effectiveness of production
equipment and processes
How is this Accomplished?
» By improving On Demand availability of
the equipment, through improved
maintenance
TPM
Introduction
How is this Different from Other
Maintenance Programs?
» Primary difference between TPM and
most maintenance programs is the
involvement of the machine operator as
a front line defense against…
– Equipment breakdowns and other unplanned
downtime
– Scrap and rework caused by poor equipment
performance
– Reduced productivity due to running at
reduced speeds, idling, or stoppages requiring
operator attention
– Equipment startup losses
TPM
Introduction
Brief History of TPM
» Preventative maintenance originated in the United
States in 1940’s
» Japanese auto manufacturers studied these methods in
the 1950’s
» First true TPM initiative developed by Nippondenso in
the late 1960’s
» First true TPM in the United States developed by
Kodak’s Tennessee Eastman facility in 1987
TPM
Why is TPM Important?
TPM
Why is TPM Important
TPM
Why is TPM Important
TPM
Why is TPM Important – Benefits
WHY???
» Maximizes the productivity of equipment for its entire
life cycle
» Extends equipment life
» Increases the amount of time equipment can be doing
what we need it to do
» Builds / Trains a workforce that can most effectively
help the organization best utilize it’s equipment
TPM
Why is TPM Important – Benefits
WHY??? To reduce Waste?
» Equipment Breakdowns
» Setup and Adjustment Delays
» Idling and minor stoppages
» Reduced Speed
» Process Defects
» Reduced Yield
TPM
Typical Maintenance Strategies
TPM
Typical Maintenance Strategies
Types
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Reactive
Preventive
Predictive
Corrective Maintenance
Maintenance Elimination
» All of these can have a place, yet some better
than others
TPM
Typical Maintenance Strategies
Most Common Strategy?
“If it ain’t broke,
don’t fix it”.
» Reactive Maintenance
TPM
Typical Maintenance Strategies
Reactive Maintenance = 55%
» Advantages
• Low cost
• Less staff
» Disadvantages
• Increased cost due to unplanned downtime
of equipment
• Increased labor cost, especially if overtime
is needed ,cost involved with repair or
replacement of equipment.
• Possible secondary equipment or process
damage from equipment failure.
• Inefficient use of staff resources.
TPM
Typical Maintenance Strategies
Can we get better?
Time or Machine
cycle based
maintenance
functions
» Preventive Maintenance
TPM
Typical Maintenance Strategies
Preventive Maintenance = 31%
» Developed by US Navy
» Advantages
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Cost effective in many capital-intensive processes
Flexibility allows for the adjustment of maintenance schedules
Increased component life cycle
Energy savings
Reduced equipment or process failure
Estimated 12% to 18% cost savings over reactive maintenance program.
» Disadvantages •
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Catastrophic failures still likely to occur
Labor intensive
Includes performance of unneeded maintenance
Potential for incidental damage to components in conducting unneeded maintenance.
TPM
Typical Maintenance Strategies
Anything Better?
Maintenance
functions based on
feedback,
predicting that
something needs to
be done.
» Predictive Maintenance
TPM
Typical Maintenance Strategies
Predictive Maintenance = 12%
» Advantages
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Increased component operational life/availability.
Allows for preemptive corrective actions.
Decrease in equipment or process downtime.
Decrease in costs for parts and labor.
Better product quality.
Improved worker and environmental safety.
Improved worker morale.
Energy savings.
Estimated 8% to 12% cost savings over preventive maintenance
program.
» Disadvantages
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Increased investment in diagnostic equipment.
Increased investment in staff training.
Savings potential not readily seen by management.
TPM
Typical Maintenance Strategies
More?
Modifying a piece of
equipment such
that it will last
longer.
» Corrective Maintenance
TPM
Typical Maintenance Strategies
More?
Removing or reducing
the need for
maintenance to
occur
» Maintenance Elimination
TPM
What Does TPM Look Like?
TPM
What Does TPM Look Like?
TPM Implemented?
» Machine Operators are trained to do much of the
maintenance operations, and it’s part of their Standard Work
TPM
What Does TPM Look Like?
TPM Implemented?
» Tools necessary are readily available
TPM
What Does TPM Look Like?
TPM Implemented?
» Equipment modified such that easy to keep clean, easy to
see when maintenance is required.
Before
After
TPM
What Does TPM Look Like?
TPM Implemented?
» More examples of easily cleaned and seen
Filtered Air
Before
After
TPM
What Does TPM Look Like?
TPM Implemented?
» More examples of easily cleaned and seen
Before
After
TPM
What Does TPM Look Like?
TPM Implemented?
» Equipment modified such that easy to maintain
TPM
How to Implement?
TPM
How To Implement?
How To….
1. Select Equipment to work on
2. Begin with 5Sing, Initial Clean Up
3. Define Machine Operator Maintenance Tasks
• Modify equipment to facilitate tasks
4. Define Maintenance Technician Tasks
• Provide “informative” tools to assist
5. Sustain
TPM
How To Implement? | Equipment Selection
How To….
1. Select Equipment to work on….
• Equipment that is giving you problems with…
• Unplanned downtime
• Excessive quality problems
• Excessive repair costs
• Premature “end of life” failures
• Running slower than “design” to prevent breakdowns
TPM
How To Implement? | Equipment Selection
How To….
2. 5S Event….
• Improves ability to perform regular inspections
• Allows the discovery of potential problems
• Log problems and potential problems and develop an
immediate action plan
• Mark all lubrication, fluid connections and directions, etc
• Paint equipment
TPM
How To Implement? | Equipment Selection
How To….
3. Defining Machine Operator Tasks
• Develop Standards and Checklists
• Cleaning
• Lubrication
• Visual Checks
• Procedures to keep equipment “as new”
TPM
How To Implement? | Equipment Selection
How To….
3. Make Machine Operator maintenance tasks easier/quicker
• Easy to see when things need to be maintained
• Lubrication needs become obvious to operator
• Routine cleaning operations easier
• Machine disassembly minimized
• Automate maintenance when possible
• Clear signals when maintenance is needed
TPM
How To Implement? | Equipment Selection
How To….
3. Defining Machine Operator Tasks (cont.)
• Train Operators on….
• Visual checks
• Hydraulics
• Electrical / electronics
• Mechanical drive systems
• Complex lubrication
• Safety
• Procedures for minor repair and replacement
• Criteria delineating operator and technician
approved activities
TPM
How To Implement? | Equipment Selection
How To….
3. Defining Machine Operator Tasks (cont.)
• Implement Daily Operator Activities
• Review checklists with operators
• Ensure operator training is complete
• Finalize checklist schedules
TPM
How To Implement? | Equipment Selection
How To….
4. Define Maintenance Tech Tasks (Reactive)
• Provide Tech support to operator questions
• Provide clear communication path
• Spare Parts Program
• Equip Manufacturer recommendations
• Breakdown History Data
• Kanban
TPM
How To Implement? | Equipment Selection
How To….
4. Define Maintenance Tech Tasks (Preventive)
• Eliminate Equipment Deterioration
• Scheduled general inspections
• Equipment overhauls
• Triggered by checklists
• Identify and Resolve Chronic Problems
• Breakdown history log
• Root cause analysis methods
• 5 Why analysis
TPM
How To Implement? | Equipment Selection
How To….
4. Define Maintenance Tech Tasks (Predictive)
• Develop and Analyze Equipment History
• Plot failure history
• Correlate with Equipment Quality Performance
• Determine Equipment Parameters That Predict
Failure
• Use information from equipment manufacturer
• Oil, vibration, temperature analysis
• Develop Equipment Monitoring Systems
• Ensure appropriate accuracy and tolerance
• Lease equipment to ensure usability before
purchase
TPM
Sustain
TPM
Sustain
Sustaining….
» Measuring progress / status is key to sustaining
» Primary Measurement tool is OEE
» OEE – Overall Equipment Effectiveness, is
measured….
OEE = Equip Availability X Performance Efficiency X Quality Rate
» Audit machine operator’s standard work
» Audit maint tech’s standard work
TPM
Summary
TPM
Summary
» TPM is a method for continuously
improving the effectiveness of production
equipment and processes
» By improving On Demand availability of
the equipment, through improved
maintenance
» With a primary focus on involving
machine operators in routine
maintenance
» And making that maintenance easily
seen, easily done, and effective
TPM
Q&A
TPM