TOTAL PRODUCTIVE MAINTENANCE

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TOTAL PRODUCTIVE MAINTENANCE
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What is TPM?

• TPM is a manufacturing led initiative that
  emphasizes the importance of people, a can do
  and continuous improvement philosophy and the
  importance of production and maintenance staff
  working together.

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Main Concerns

• Fundamental rethink of business process to
  achieve improvements in cost, quality, speed, etc.

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Encourages

• Flatter organization structures
• Multiskilled workforce
• Rigorous appraisal of the way things are done

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Principal Measure

• Overall equipment Effectiveness (OEE)
• OEE A x PE X Q
• Metrics
• Time (availability A)
• Speed (performance PE _at_ Output rate)
• Quality (yield Q)

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Six Big Losses

• Equipment downtime
• Engineering adjustment
• Minor stoppages
• Unplanned breaks
• Time spent making reject products
• Waste
• Speed losses

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The 5 Goals (Pillars)

• Improve equipment effectiveness
• Achieve autonomous maintenance
• Plan maintenance
• Train all staff in relevant maintenance skills
• Achieve early equipment management

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More Pillars

• Process quality management
• TPM in administrative and support department
• Safety and environmental management

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Elemental Requirements

• Total commitment from the top management
• Appropriate diffusion of the plan and its results
• Authentic improvement and mutual respect at all
  levels

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Additional Requirements

• Reliability
• Total Cost of Ownership
• Developing preventive maintenance program
• Training workers to operate and maintain machines

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Types of Maintenance

• Breakdown maintenance
• Preventive maintenance
• Corrective maintenance
• Maintenance prevention

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Results and Achievements

• 15-25 improvement in equipment operation rate
• Labor productivity increases as high as 40-50

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Achievements

• Better understanding of the performance of the
  equipment
• Better understanding of equipment criticality and
  where it worth deploying improvement effort and
  potential benefits
• Improved teamwork and reduce adversary between
  Production and maintenance
• Increase enthusiasm of the workforce

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Steps in introducing TPM into an organization

• Preparatory stage
• Announcement by Management
• Initial education and propaganda
• Setting up of TPM and department committee
• Establishing TPM working system and target
• A master plan for institutionalizing

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Steps in introducing TPM into an organization

• Introduction Stage
• Analysis
• Maintenance definitions
• Problems definitions
• Tasks definitions

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Steps in introducing TPM into an organization

• Implementation Stage
• Put plan into action
• Leadership
• Change
• The determination of the tasks sequence
• The determination of people and specific tasks
• Evaluation

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Steps in introducing TPM into an organization

• Institutionalizing Stage
• Standard Operating Procedure

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Lower Ops Cost
Faster, more dependable throughout
Reduced Inventory
Higher Productivity
TPM
Improved Capacity
Improved Quality
Continuous Improvement
BENEFITS