Total productive maintenance

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Partners for Creative Solutions, Inc.36 Deerfield Rd, Shrewsbury, MA 01545508 845-1546 [email protected]

Total Productive MaintenanceTotal Productive Maintenance

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Partners for Creative Solutions, Inc.

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TPM Training AgendaTPM Training Agenda

TPM – History, benefits and typical results Definition and “5 Pillars” of TPM The “6 Big Losses” Autonomous Maintenance Maintenance Prevention Setting Standards & Sustaining the Benefits TPM and Safety The Advisory Team Equipment Improvement Teams (EIT’s) TPM vs. 5S Summary of TPM topics

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Origins of TPMOrigins of TPM

Breakdown maintenance (RTF) - historical

Preventive Maintenance concept – introduced in1951

Productive Maintenance introduced later Included

Preventive maintenance Improvement-related maintenance Maintenance prevention

Still primarily maintenance department Never achieved zero breakdowns or defects

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Origins of TPMOrigins of TPM

Total Productive Maintenance Brought operators into the picture Small group activities Teamwork between operators and maintenance Involvement & support throughout the company

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No Tolerance for Breakdowns No Tolerance for Breakdowns

Equipment breakdowns impact Customer service Production costs Maintenance costs Effectiveness of “manufacturing cells” or “flow

lines”

Breakdowns result in “chaos”

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The Last 50 YearsThe Last 50 Years

In the 1950’s, about 70% of durable goods sold in the world were made in the U.S. …today << 10%

In the 1950’s, there were over 25 U.S. television manufacturers …by the early 1990’s, only 1 (Zenith) …today??

In the 1950’s, the largest growing job was in manufacturing…not the case today!!

Most manufacturing industries are fighting a war to survive!

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Benefits of TPM to the CompanyBenefits of TPM to the Company

Improved plant productivity and capacity

Lower operating costs

Improved equipment lifespan

Better ability to satisfy customers

Bottom Line: TPM increases long-term viability

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Benefits of TPM for Operators & Maintenance Personnel

Benefits of TPM for Operators & Maintenance Personnel

Increased skills through additional training

Better job satisfaction Operators – More involvement in solving annoying

equipment problems Maintenance – More challenging work

Better job security

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Typical TPM ResultsTypical TPM Results

Overall equipment effectiveness up 25-65%

Quality defects down 25-50%

Maintenance expenditures down 10-50%

Percent planned vs. unplanned maintenance increased 10-60%

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DefinitionDefinition

TPM is a company-wide system developed to maintain, monitor, and improve all capital assets of a company. For production it is a system that maximizes equipment effectiveness and maintains product flow. TPM is not just about “maintenance”. It is about

getting the most overall benefit from your equipment over the life of the equipment.

TPM will not be an overnight success. Implementing it throughout a plant correctly will take several years.

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Shift in AttitudesShift in Attitudes

Operator Maintenance Operator Maintenance

Conventional TPM

I use I maintain &I fix

We maintain

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5 Pillars of TPM5 Pillars of TPM

1. Improvement activities designed to increase equipment effectiveness (OEE)

2. Autonomous maintenance program performed by equipment operators

3. A planned maintenance system

4. Training to improve operation & maintenance skills

5. Effective new equipment design and startup

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TPM Emphasizes PreventionTPM Emphasizes Prevention

Three Principles of Prevention

1. Maintain normal conditions

2. Early discovery of abnormalitiesa) Operatorb) Maintenance

3. Prompt response

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The Six Big Equipment LossesThe Six Big Equipment Losses

1. Breakdowns

2. Setups and adjustment

3. Idling and minor stoppages

4. Speed

5. Quality defects and rework

6. Start-up (loss of yield)

Overall equipment effectiveness = Availability x Performance rate x Quality rate (OEE)

BreakdownSetup and adjustment Others Idling & minor stoppages

Reduced speed

Quality defects & reworkStart-up yield

Operation time (Scheduled time available – Downtime)Availability = ______________________________________________ x 100

Scheduled time available

processed amount x ideal cycle timePerformance rate = _____________________________

Operation time

Quality rate = Amount good / amount produced

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Improving OEEImproving OEE

1. Measure the extent of the 6 big losses

2. Analyze the causes (but focus your efforts )

3. Develop solutions & create an improvement plan

4. Set targets and estimate the benefits to OEE

5. Carry out the plan

6. Establish measurements to monitor results

7. Repeat as necessary

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Eliminating BreakdownsEliminating Breakdowns

Workplace Conditions Contribute to Losses Filthy equipment

Oil and lubricant leaks

Moving parts encrusted with raw materials or debris

Disorderly wiring, hoses, etc.

Equipment mechanisms hidden or difficult to access

Workplace disorder

A belief that conditions cannot improve

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Why machines fail Disregard for basic needs (housekeeping, lube..) Incorrect operating conditions Lack of skill or knowledge of operator Machine deterioration

Routine Accelerated

Design deficiency

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Two kinds of breakdowns Function loss (function completely lost) - Sporadic Function reduction (works, but with loss of speed or

quality) - Chronic

Two kinds of breakdown maintenance Planned (pre-emptive) Unplanned (firefighting)

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Autonomous MaintenanceAutonomous Maintenance

The principal way production workers participate in TPM

Purpose1. Brings production & maintenance people together to

slow routine deterioration and halt accelerated deterioration

2. Helps operators learn more about their equipment (the cause and effect)

3. Prepares operators to be active partners with maintenance and engineering in improving equipment performance and reliability

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Steps to Implementing Autonomous Maintenance


Step 1: Initial cleaning and inspection

Step 2: Eliminate sources of contamination and inaccessible areas

Step 3: Develop and test cleaning, inspection, and lubrication standards

Step 4: General inspection training and inspection procedures

Step 5: Conduct autonomous general inspections

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Step 6: Organize and manage the workplace

Step 7: Ongoing autonomous maintenance and continued improvement

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An advanced Improvement methodAn advanced Improvement method

Maintenance PreventionDesign-stage activities aimed at making new equipment

reliable, easy to care for, and user friendly

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Sustaining TPMSustaining TPM

Audits Visual activity boards

Team charter Team activities, goal, schedule, and progress Cleaning, inspection, and lubrication standards Workplace organization standards Trend charts for each of the big 6 losses Inspection reports Audit results Before and after photos

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TPM and SafetyTPM and Safety

Safety is the cornerstone of

production activities

Accidents usually occur when unsafe

behavior is combined with

unsafe conditions

For every major accident there are

29 minor accidents and 300 near misses

Safety should always be the #1 priority

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Setting Up a TPM StructureSetting Up a TPM Structure

EIT

EIT

EIT

EIT

EIT

EIT

TPMAdvisory

TeamMgmt

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Advisory Team - ResponsibilitiesAdvisory Team - Responsibilities

Guide & champion TPM implementation

Assess current equipment OEE and develop a process for measuring the “6 big” losses

Develop a TPM master plan

Set plant-wide standards for TPM implementation

Monitor and evaluate progress

Serve on EIT’s

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Equipment Improvement Teams - Responsibilities

Equipment Improvement Teams - Responsibilities

Return equipment to near new condition

Investigate and reduce the “big 6” equipment losses

Transfer routine maintenance skills to operators

Set standards for routine maintenance and inspections by operators

Organize the work area for more effective/efficient maintenance

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Setting Goals for Your TPM ProgramSetting Goals for Your TPM Program

Short term – 12 months Establish an autonomous maintenance program for “x”

machines Increase OEE by “y”% within for individual work

centers

Long term – Reach a plant OEE of 85% within 3 years (world class is considered about 85%)

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Comparing TPM to 5SComparing TPM to 5S

5S emphasizes Productivity of workers Organizing and visual indicators

TPM emphasizes Effectiveness of equipment Partnership between maintenance & production Reducing lifetime equipment costs

Both emphasize Initial cleaning and repair Safety

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Shift in Equipment Maintenance Activities

Shift in Equipment Maintenance Activities

Breakdown

PM

Planned repair

FROMTHIS

to

Autonomous

PM

Predictive

Planned repair

Breakdown

THIS

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Review of TPM’s benefitsReview of TPM’s benefits

For the company Higher Overall Equipment Effectiveness Less “firefighting” to repair machines Lower operating costs Better able to meet commitments to customers Improved ability to compete in the world marketplace

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Review of TPM’s benefitsReview of TPM’s benefits

For employees Less pressure on maintenance for urgent repairs Less pressure on production to recover from

breakdown losses Better cooperation between maintenance, production,

and other departments Reduced chance of accidents Higher job satisfaction Improved job security

Technology

Total productive maintenance