WHAT IS TPM

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WHAT IS TPM
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W H A T I S TPM ?

• A well defined methodology to optimize resources
  improve performance
• A culture change - never be satisfied
• Team-work and cross functionality
• Transparency and visibility
• Discipline and rigour
• Continuous improvement
• Wireless real time data collection, data mining
  and data assessment

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16 MAJOR LOSSES

• TPM is a system to organize practical, shop-floor
  methods to reduce losses ...

EQUIPMENT 1- Failure Loss 2- Start up Loss 3-
Speed Loss 4- Set up Adjustment 5- Idling
Minor Stops 6- Defects Rework 7- Shutdown
Loss 8- Die, Jig Tool Loss
MAN POWER 10- Motion Loss 11- Measure
Adjust 12- Management Loss 13- Line
Organisation 14- Lack of Automation
MATERIAL 15- NTM, Consumables 16- Yield Loss
ENERGY 9- Energy Loss
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16 MAJOR LOSSES
Machine (machine time)
Man (Man time)
Labour efficiency
Machine efficiency
Operational time
Working time
Scheduled Downtime
Man Loading Time
Machine Loading time
Net operational time
Operational time
Production man-hour loss
Real working time
Net operational time
Downtime loss
5 major losses obstructingmanpower efficiency
major losses obstructingequipment efficiency
Value added time
Value added time
Line organisationman-hour loss
Performance loss
Defect in man-hour loss
Defects quality loss
Energy
Material
Material input (number, weight)
Energy input
Effective energy
N. quality products
Ideal weight of quality products
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W H A T I S TPM ?
in other words INCREASE THE RELIABILITY OF THE
PLANT
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T E C H N I Q U E S o f TPM
- Cleaning - Tagging - 5 S - Details 1 / 30 /
300 - Teams - Loss Deployment - Audits -
Communication Boards - One Point Lessons (OPL)
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C U L T U R E C H A N G E
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COMPANY LANGUAGES
Source Juran
CAN SPEAK ALL COMPANY LANGUAGES
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TPM ORGANISATION
BOARD
AMAUTONOMOUS MANAGEMENT PM PROGRESSIVE
QUALITY FIFOCUSED IMPROVEMENT
OVERALL WCMCOORDINATOR
Machine (machine time)
Man (Man time)
PLANT WCM COORDINATOR
Machine (machine time)
PLANT STEERING COMMITTEE STRUCTURE

DEPARTMENTAL COMMITTEE STRUCTURE
AREA COMMITTEE STRUCTURE
TPM TEAM STRUCTURE
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LOSS DEFINITION
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LOSSES OF UPTIME
AUTONOMOUS MANAGEMENT TEAMS
PROGRESSIVE QUALITY TEAMS
PLANNED MAINTENANCE TEAMS
FOCUSED IMPROVEMENT TEAMS
These teams attack individual loses with
different methodologies
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LOSS DEPLOYEMENT OF UPTIME (OEE)
100
UPTIME IS AN INDICATION ON WHAT WE DO
GOOD THE PORTION ABOVE UPTIME THAT SUMS UP TO
100 SHOWS THE LOSSES LOSSES NEEDS TO BE DEFINED
AND DEPLOYED SYSTEMATICALLY FOR GOOD ANALYSIS