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Objectives of TPM
TPM Concepts
Autonomous Maintenance
Planned Maintenance
Maintenance Reduction
Equipment Effectiveness
Equipment Availability
Equipment availability = [Actual Operating Time/ Net available Run Time] x 100
Performance Efficiency
Performance Efficiency = [(Design Cycle Time x Total output for Operating Time) /
Actual Operating Time] x 100
Quality Rate
Quality Rate = [(Total output for Operating Time - Rejects)/ Total output for Operating
Time] x 100
2016
Quiz 1: Tuesday, 23rd February, 2016
Breakdowns
Proactive replacement during scheduled maintenance
Reduced Speed
Excessive equipment wear
Idling and Minor Stops
Equipment jams
Process Defects
Improving equipment
Startup Losses
Product waste until operating temperature
Increased Productivity
Less unscheduled downtime
More time to value added tasks
Workers also increase productivity
Reduced Maintenance Costs
Proactive improvement
Firefighting approach to extra staff members
Autonomous maintenance
Reduced Inventory
Unreliable equipment results in large stocks of finished goods
Reduced spare parts inventory
Improved Safety
Safety of operators
Improved Morale
Operators in drivers seat
Maintenance technicians time for equipment analysis and designers
Problem: A factory is running 6 days a week with two shifts per day. There are 12 hours in one
shift. The planned downtime is 297 minutes and downtime losses are 752 minutes. Total output
for operating time is 57AAA units. Design cycle time is 0.126 minutes/ unit. Rejects are 500
units. Calculate the overall equipment effectiveness