Total Productive Maintenance

Total Productive Maintenance,[object Object],TPM - Why, What, Where, Who ..,[object Object],Anand Subramaniam,[object Object]

2,[object Object],“Another flaw in the human character is that everybody wants to build and nobody wants to do maintenance.” ,[object Object],- Kurt Vonnegut,[object Object]

3,[object Object],Highlights,[object Object],TPM – Overview,[object Object],TPM, TQM, 6S,[object Object],TPM Pillars,[object Object],Losses / Waste / 3 Zero,[object Object]

TPM - Overview,[object Object]

Lean System,[object Object],5,[object Object],Peak Performance,[object Object],Pull system / flow production,[object Object],Rapid Changeover / Customer-driven lot size,[object Object],Continuous Waste Reduction,[object Object],Lean Measures,[object Object],5S ,[object Object],Visual Factory,[object Object],Standardised Work,[object Object],T P M,[object Object],Variation reduction / Six Sigma,[object Object],In-Station Process Control,[object Object],Leadership by Example & Commitment,[object Object],Employee Involvement & Mutual Respect,[object Object]

Current Challenges,[object Object],High numbers of component parts,[object Object],Lack of innovation / new ideas & change management,[object Object],Huge Losses – high set up, breakdown, defects, adjustment, reduced speed, yield & productivity,[object Object],Low-quality products & services,[object Object],Workforce lack - skills, training, co-ordination, accountability, responsibility,[object Object],Challenges,[object Object],Work place – unsafe, dirty, & untidy,[object Object],Lack of growth potential,[object Object],Lack and / or complicated production procedures,[object Object],Badly designed, outmoded & many "bottleneck” processes,[object Object],High Operational Costs,[object Object],6,[object Object]

Total ,[object Object],All encompassing by maintenance and production individuals working together,[object Object],[object Object]

Aim - to eliminate all accidents, defects and breakdownsProductive,[object Object],Production goods and services that meet or exceed customers’ expectations,[object Object],[object Object]

Production challenges are minimisedMaintenance,[object Object],Keeping equipment and plant in as good as or better than the original conditions at all times,[object Object],[object Object]

Repair, clean, lubricateTPM,[object Object]

TPM - What,[object Object],Plant improvement methodology,[object Object],Build quality into equipment maintenance,[object Object],Company wide strategy for equipment, process improvement & a team based effort ,[object Object],A Lean Tool to optimise the effectiveness of manufacturing equipment,[object Object],Continuous improvement of manufacturing process using tools of TQM,[object Object],What,[object Object],Closed-loop measurement of results,[object Object],Aka Autonomous Maintenance, where users take time to clean, inspect & carry out basic maintenance on their equipment.,[object Object],Employee involvement, & empowerment,[object Object],8,[object Object]

TPM - Why,[object Object],9,[object Object],Organisation,[object Object],[object Object]

Less “firefighting” to repair machines

Better able to meet commitments to customers

Improved ability to compete in the world marketplaceEmployees,[object Object],[object Object]

Better cooperation between maintenance, production, and other departments

Higher job satisfaction & improved job security,[object Object]

TPM - Principles,[object Object],Involve everyone & utilise cross-functional teamwork,[object Object],Provide training to upgrade operations & maintenance skills,[object Object],Starts with 5S / Visual Factory,[object Object],Use Overall Equipment Effectiveness (OEE) as a compass for success,[object Object],Improve existing planned maintenance systems,[object Object],Principles,[object Object],Complete elimination of the ‘six major losses’ while striving for a goal of zero unscheduled downtime,[object Object],Reduce life cycle cost,[object Object],11,[object Object]

TPM – Goals,[object Object],Maintaining Equipment for life and Increase production quality,[object Object],Obtain support and cooperation from top managers to all levels,[object Object],Encourage input from all employees,[object Object],Use teams for continuous improvement,[object Object],Goals,[object Object],Empower and increase job satisfaction,[object Object],Build a comprehensive plant maintenance system based on autonomous small group activities,[object Object],Bring together people from all departments concerned with equipment,[object Object],12,[object Object]

13,[object Object],TPM - Strategies,[object Object],Initial,[object Object],Control,[object Object],System,[object Object],Planned,[object Object],Mainten-ance,[object Object],System,[object Object],Operator,[object Object],Autono-mous,[object Object],Mainten-ance,[object Object],Loss,[object Object],Elimination,[object Object],TPM Strategies,[object Object],Education,[object Object],& ,[object Object],Training,[object Object],3 Zeros - ,[object Object],Defects , Accidents, & Failures,[object Object]

TPM - Benefits,[object Object],Improved capacity & higher productivity,[object Object],Reduced emergency downtime,[object Object],Increased employee skill levels and employee empowerment,[object Object],Increased equipment FPY (first pass yield) / FTT (first time through) ,[object Object],Preventive maintenance costs reduced as equipment operators conduct autonomous maintenance,[object Object],Benefits,[object Object],Engineers, technicians and managers trained in maintenance and quality,[object Object],Improved equipment design eliminates the root cause of defects,[object Object],Increased return on investment,[object Object],14,[object Object]

TPM – Measures,[object Object],15,[object Object],Short Term,[object Object],[object Object]

Increase OEE by “y”% within for individual work centersLong Term,[object Object],[object Object],[object Object]

TPM & TQM Similarities,[object Object],Employees empowered to initiate action,[object Object],On-going, continuous process improvement,[object Object],Both requires Senior Management commitment,[object Object],Long term outlook, TPM take time to implement & sustain,[object Object],17,[object Object]

TPM & TQM Differences,[object Object],18,[object Object]

Total Productive Maintenance

Total Productive Maintenance

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