TPM “Basics” Decision Tree TPM Pilot Flowchart

Starting TPM 1. Management Commitment

to Pursue TPM

1. Do We Have a PM 2. Pilot Areas Readiness

Develop a PM Program
Program? Assessment
SELECTING...
2. Evaluate the Effectiveness 2A. Review Potential
Of the PM Program Pilot Areas

High
Constraint High Added Capacity Quality
3. Is It Effective - <20% Reactive Implement Effective Maintenance
Equipment? Downtime? Needed? Problems?
Work Performed? PM Procedures Cost?

4. Review Maintenance Stores 2B. Select Pilot Area

- Operations/Manufacturing
- Maintenance
2C. Determine Natural - Process Improvement
Develop Effective Work Group - Engineering
5. Are Stores Effective -
Stores Procedures - Quality
>95% Service Level? - Other Support
2D. Identify Readiness:
6. Review Work Order System

Willing Management Willing Early Results

7. Are Work Orders Fully Implement an Effective Workforce? Possible?
& Supervision
Utilized (100% Coverage)? Work Order System

2E. Identify Basics In Place

8. Review Planning & Scheduling or Needed:

9. Is Planning & Implement Effective Maintenance Trained Trained Performance Equipment

Scheduling Effective - Maintenance Planning & Basics? Operators? Maintainers? Tracking? Management?
>80% Weekly Scheduling
- CMMS
- Preventive Maintenance
10. Investigate Computerization - Lubrication
Of Work Order System - Spare Parts 2F. Determine Schedules:
- Work Requests/Orders
10a. Establish
Does the Work Order 10b. Is the Manual
a Manual Meetings Maintenance
System Require System Shift/Days Training Time On-Job Training
Maintenance Shutdowns
Computerization? Effective?
System

10c. Evaluate Work 2G. Develop Preliminary

11. Purchase & Implement Plan & Schedule
Order Process.
A CMMS (EMIS)
DEVELOPING... 3. Pilot Area Preparation
12. Is the CMMS Identify &
Usage Effective? Correct Problems 3A. Work Group TPM
Orientation:

13. Investigate Operator Involvement

To Selecting & Developing TPM Why Area Was Opportunities
In Pilot Area What Is TPM?
Pilot Area (Step 1) Selected

Are There Activities the 3B. Form Area TPM

Re-evaluate the
Operators Could Be Involved In? Design Team
Activities
3C. Design Team
- Operator Cleaning & Inspecting TPM Education
14. Identify the Activities - Work Requests
- Visual Systems 3D. Identify TPM Starting
Points:
Train & Certify the
15. Are the Operators Certified to Operators to Perform Tracking,
Perform the Activities? Enhance The Operator
the Activities Work Request Reporting, Visual Systems
“Maintenance Cleaning &
System Analyzing For TPM
Basics” Inspecting Performance
To Selecting &
16. Begin Operator Involvement Developing TPM Pilot
3E. Develop Detailed
Areas (Step 6)
Plan & Schedule

17. Is Predictive Maintenance Begin Predictive Maintenance

Being Performed?
18. Investigate Reliability Engineering
Is Reliability Data Used for
All Equipment Making Decisions?
19. Investigate Financial
Optimization
3F. Conduct Focused Training
- Life Cycle Costing
-RCM
4. Apply TPM Learning
-FEMA
- Early Equipment Management & Design
4A. Monitor Performance:
Begin Using Reliability
Engineering Techniques Refocus
Refine & Develop
Starting Point
- Total Cost Analysis
EXPANDING... 5. Improved Equipment
- All Potential Costs Related to Equipment Performance
Decisions Are Calculated

6. Enhance TPM Pilot Initiatives:

20. Are the Tools & Data Available Develop the Tools & Data
for Financial Optimization?
Operator Performed Autonomous Predictive
Other
Re-evaluate Previous Maintenance Maintenance Maintenance
21. Use Financial Optimization Decisions

7. Improved Equipment
Performance
22. Are We Successful Investigate Problems
With TPM? & Correct
8. Expand TPM? Continue or Stop

23. Strive for Continuous Improvement

Step 2: “Pilots Area Readiness
www.RedVector.com Assessment”