TOTAL PRODUCTIVE

MAINTENANCE [TPM]
MAINTENANCE ENGINEERING
Outline

1. TPM definition
2. Origin of TPM
3. TPM Principles
4. Eight Major Pillars of TPM
5. Requirements for Fundamental Improvement
 Preparation
 Kick-off
 Implementation
 Stabilization
 1. TPM DEFINITION

A company-wide team-based effort to build quality into equipment and to

improve overall equipment effectiveness
 Total
 all employees are involved
 it aims to eliminate all accidents, defects and breakdowns
 Productive
 actions are performed while production goes on
 troubles for production are minimized
 Maintenance
 keep in good condition
 repair, clean, lubricate
 1. TPM DEFINITION

 TPM combines the traditionally American practice of

preventive maintenance with Total Quality Control and
Total Employee Involvement, to create a culture where
operators develop ownership of their equipment, and
become full partners with Maintenance, Engineering and
Management to assure equipment operates properly
everyday.
MAINTENANCE OBJECTIVES

PLANT
Maximising Production Reduce Breakdowns
M
A
Minimising Energy Reduce Downtime
Usage
I
N
Optimising Useful Life T Improving Equipment
of Equipment Efficiency
E
Providing Budgetary
N Improving Inventory
Control A Control
N
Optimising Resources C Implementing Cost
Utilisation Reduction
E

Figure 2.3 Maintenance Objectives

 2. ORIGINS OF TPM

 Dr. Deming introduced statistical analysis and used the

resulting data to control quality during manufacturing
(TQM)
 Some general concepts of TQM did not work well in the
maintenance environment
 The need to go further than preventive maintenance was
quickly recognized by those companies who were
committed to TQM
 Maintenance became an integral part of TQM in the early
90’s
 3. TPM PRINCIPLES

 Increase Overall Equipment Effectiveness (OEE)

 Improve existing planned maintenance systems
 The operator is the best condition monitor
 Provide training to upgrade operations and maintenance
skills
 Involve everyone and utilize cross-functional teamwork
 Autonomous Maintenance

Planned Maintenance

Equipment And Process Improvement

Early Management Of New Equipment

Education And Training Process Quality Management

4. EIGHT MAJOR PILLARS OF TPM

Safety And Environmental Management

TPM In The Office

4.1. AUTONOMOUS MAINTENANCE

 Train the operators to close the gap between them and

the maintenance staff, making it easier for both to work
as one team
 Change the equipment so the operator can identify any
abnormal conditions and measure deterioration before it
affects the process or leads to a failure

 7 steps are implemented to progressively increase

operators knowledge, participation and responsibility for
their equipment
 1. Perform initial cleaning and inspection
 2. Countermeasures for the causes and effects of dirt and
dust
 4.2. EQUIPMENT & PROCESS IMPROVEMENT
Objective:
 maximize efficiency by eliminating waste and manufacturing losses
Downtime Equipment Failure / Breakdowns
Loss Set-up / Adjustments
Equipment Minor Stopping / Idling
Losses Speed Loss
MANUFACTURING (6) Reduced Speed

LOSSES Process Errors

Quality Loss
Rework / Scrap
are
Cleaning And Checking
categorized Manpower Waiting Materials
Losses
in (4) Waiting Instructions

Waiting Quality Confirmation

13 big losses
Material Yield
Material
Losses Energy Losses
(3)
Consumable Material Losses
 OEE figures are determined by combining the availability and
performance of your equipment with the quality of parts made
4.2. EQUIPMENT & PROCESS IMPROVEMENT
4.2.3 OVERALL EQUIPMENT EFFECTIVENESS (OEE)
 OEE measures the efficiency of the machine during its planned loading
time. Planned downtime does not effect the OEE figure.

Overall Equipment Effectiveness = Availability x Performance x Quality Yield

Availability Downtime loss

Performance Speed loss

Quality Yield Quality loss

 4.2. EQUIPMENT & PROCESS
IMPROVEMENT
4.2.3 OVERALL EQUIPMENT
EFFECTIVENESS (OEE)

Overall Equipment Effectiveness = Availability x Performance x Quality Yield

Availability = time available for production - downtime

time available for production

Performance = ideal cycle time x number of parts produced

operating time

Quality Yield = total number of parts produced - defect number

total number of parts produced
 4.3. PLANNED MAINTENANCE

Objective:
 establish Preventative and Predictive Maintenance systems for equipment
and tooling

 Natural life cycle of individual machine elements must be achieved

 Correct operation
 Correct set-up
 Cleaning
 Lubrication
 Retightening
 Feedback and repair of minor defects
 Quality spare parts
4.4. EARLY MANAGEMENT OF NEW
EQUIPMENT

Objective:
 establish systems to shorten
 new product or equipment development
 start-up, commissioning and stabilization time for quality and efficiency

 New equipment needs to be:

 easy to operate
 easy to clean
 easy to maintain and reliable
 have quick set-up times
 operate at the lowest life cycle cost
 4.5. PROCESS QUALITY MANAGEMENT

DEFINITION:
 a process for controlling the condition of equipment components that affect
variability in product quality
OBJECTIVE:
 to set and maintain conditions to accomplish zero defects

 Quality rate has a direct correlation with

 material conditions
 equipment precision
 production methods
 process parameters
 4.6. TPM IN
ADMINISTRATIVE & SUPPORT
DEPARTMENTS

 Administrative and support departments can be seen as process

plants whose principal tasks are to collect, process, and distribute
information
 Process analysis should be applied to streamline information flow
 4.7. EDUCATION & TRAINING

 TPM is a continuous learning process.

 2 major components
 soft skills training: how to work as teams, diversity training
and communication skills
 technical training: upgrading problem-solving and equipment-
related skills
 4.8. SAFETY & ENVIRONMENTAL
MANAGEMENT

 Assuring safety and preventing adverse environmental impacts are

important priorities in any TPM effort
 5. REQUIREMENTS FOR
FUNDAMENTAL
IMPROVEMENT
3 REQUIREMENTS FOR FUNDAMENTAL
IMPROVEMENT
 Increasing motivation: changing peoples attitudes
 Increasing competency and peoples skills
 Improving the work environment, so that it supports the
establishment of a program for implementing TPM
 Announcement to introduce TPM
5. TPM IMPLEMENTATION (12
Introductory education campaign for STEPS)
the workforce
Preparation TPM Promotion (special committees)

Establish basic TPM policies and goals

Preparation and Formulation of a master plan

Kick-off Invite customers, affiliated companies and subcontractors

Develop an equipment management program

Develop a planned maintenance program
Implementation Develop an autonomous maintenance program
Increase skills of production and maintenance personnel
Develop early equipment management program

Stabilization Perfect TPM implementation and raise TPM levels

 TPM PREPARATION
5.1. Announce Top Management’s Decision To Introduce TPM
 State TPM objectives in a company newsletter, Place articles on TPM in the company
newspaper
5.2. Introductory Education Campaign
 Seminars for managers, Slide presentations for all employees
5.3. TPM Promotion
 Special committees at every level to promote TPM
 Newsletters/Articles/Videos/Posters
5.4. Establish Basic TPM Policies And Goals
 Analyze existing conditions, Set goals, Predict results
5.5. Preparation and Formulation of a Master Plan
 A master plan lays out your goals, what you will do to achieve them and when you
will achieve them
 Detailed plans for each pillar have to be prepared
 TPM KICK-OFF

5.6. Invite Customers, Affiliated Companies &

Subcontractors
 The main kick-off to TPM should take the form of a formal
presentation with all the employees attending
 This opportunity can be used to gain the full support of the
employees
 Invite external customers, affiliated and subcontracting
companies
 TPM IMPLEMENTATION

5.7. Develop An Equipment Management Program

 The tools of Total Quality Management and Continuous Improvement are
applied to the management and improvement of equipment
 Form project teams
 Select model equipment
• identify equipment problems
• analyze equipment problems
• develop solutions and proposals for improvement

 Typical membership of a team

• five to seven operators
• a maintenance person
• a technical experts
 TPM IMPLEMENTATION

5.8. Develop A Planned Maintenance Program

 Set up plans and schedules to carry out work on equipment before it breaks down,
in order to extend the life of the equipment
 Include periodic and predictive maintenance
 Include management of spare parts and tools

5.9. Develop a Autonomous Maintenance Program

 A handing-over of maintenance tasks from specialized maintenance personnel to
production operators
 Promote the seven steps
 Tasks to hand over
 Cleaning, lubricating, inspecting, set-up and adjustment
 TPM IMPLEMENTATION

5.10. Increase skills of production and maintenance personnel

 The training sessions must be planned shortly after the kick-off
presentation.
 2 major components
 soft skills training
 technical training
 Train leaders together
 Have leaders share information with group members
 TPM IMPLEMENTATION

5.11. Develop Early Equipment Management Program

 The principle of designing for maintenance prevention can be applied to new
products, and to new and existing machines.
NEW PRODUCTS
 must be designed so that they can be easily produced on new or existing
machines
NEW MACHINES
 must be designed for easier operations, changeover and maintenance
EXISTING MACHINES
 analyze historical records for trends of types of failures, frequency of component
failures, root causes of failures
 determine how to eliminate the problem and reduce maintenance through an
equipment design change or by changing the process
 TPM STABILIZATION

5.12. Perfect TPM implementation and raise TPM levels

 Increased equipment productivity
 Reduced equipment downtime
 Increased plant capacity
 Lower maintenance and production costs
 Approaching zero equipment-caused defects
 Enhanced job satisfaction
 Increased Return On Investment