Total Productive Maintenance

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Total Productive Maintenance
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AGENDA
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Agenda
AGENDA

• Introduction To TPM
• Why Benefits?
• Typical Maintenance Strategies
• What Does TPM Look Like?
• How to Start Using TPM
• Sustaining
• Summary / Questions

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INTRODUCTION
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What is TPM?
Introduction

• 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

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How is this Different from Other Maintenance
Programs?
Introduction

• 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

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Brief History of TPM
Introduction

• Preventative maintenance originated in the United
  States in 1940s

• Japanese auto manufacturers studied these methods
  in the 1950s

• First true TPM initiative developed by
  Nippondenso in the late 1960s

• First true TPM in the United States developed by
  Kodaks Tennessee Eastman facility in 1987

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Why is TPM Important?
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Why is TPM Important
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Why is TPM Important
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WHY???
Why is TPM Important Benefits

• 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
  its equipment

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WHY??? To reduce Waste?
Why is TPM Important Benefits

• Equipment Breakdowns

• Setup and Adjustment Delays

• Idling and minor stoppages

• Reduced Speed

• Process Defects

• Reduced Yield

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Typical Maintenance Strategies
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Types
Typical Maintenance Strategies

• Reactive
• Preventive
• Predictive
• Corrective Maintenance
• Maintenance Elimination

• All of these can have a place, yet some better
  than others

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Most Common Strategy?
Typical Maintenance Strategies

• If it aint broke, dont fix it.

• Reactive Maintenance

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Reactive Maintenance 55
Typical Maintenance Strategies

• 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.

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Can we get better?
Typical Maintenance Strategies

• Time or Machine cycle based maintenance functions

• Preventive Maintenance

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Preventive Maintenance 31
Typical Maintenance Strategies

• Developed by US Navy
• Advantages
• 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
• Catastrophic failures still likely to occur
• Labor intensive
• Includes performance of unneeded maintenance
• Potential for incidental damage to components in
  conducting unneeded maintenance.

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Anything Better?
Typical Maintenance Strategies

• Maintenance functions based on feedback,
  predicting that something needs to be done.

• Predictive Maintenance

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Predictive Maintenance 12
Typical Maintenance Strategies

• Advantages
• 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
• Increased investment in diagnostic equipment.
• Increased investment in staff training.
• Savings potential not readily seen by management.

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More?
Typical Maintenance Strategies

• Modifying a piece of equipment such that it will
  last longer.

• Corrective Maintenance

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More?
Typical Maintenance Strategies

• Removing or reducing the need for maintenance to
  occur

• Maintenance Elimination

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What Does TPM Look Like?
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TPM Implemented?
What Does TPM Look Like?

• Machine Operators are trained to do much of the
  maintenance operations, and its part of their
  Standard Work

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TPM Implemented?
What Does TPM Look Like?

• Tools necessary are readily available

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TPM Implemented?
What Does TPM Look Like?

• Equipment modified such that easy to keep clean,
  easy to see when maintenance is required.

Before
After
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TPM Implemented?
What Does TPM Look Like?

• More examples of easily cleaned and seen

Filtered Air
Before
After
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TPM Implemented?
What Does TPM Look Like?

• More examples of easily cleaned and seen

After
Before
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TPM Implemented?
What Does TPM Look Like?

• Equipment modified such that easy to maintain

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How to Implement?
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How To.
How To Implement?
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
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How To.
How To Implement? Equipment Selection

• 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

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How To.
How To Implement? Equipment Selection

• 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

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How To.
How To Implement? Equipment Selection
3. Defining Machine Operator Tasks

• Develop Standards and Checklists
• Cleaning
• Lubrication
• Visual Checks
• Procedures to keep equipment as new

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How To.
How To Implement? Equipment Selection
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

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How To.
How To Implement? Equipment Selection
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

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How To.
How To Implement? Equipment Selection
3. Defining Machine Operator Tasks (cont.)

• Implement Daily Operator Activities
• Review checklists with operators
• Ensure operator training is complete
• Finalize checklist schedules

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How To.
How To Implement? Equipment Selection
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

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How To.
How To Implement? Equipment Selection
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

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How To.
How To Implement? Equipment Selection
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

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Sustain
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Sustaining.
Sustain

• 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 operators standard work

• Audit maint techs standard work

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Summary
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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

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QA
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