Total Productive

Maintenance
TPM

AGENDA

TPM

AGENDA

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

TPM

INTRODUCTION

TPM

Introduction

What is TPM?
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

TPM

Introduction

How is this Different from Other

Maintenance Programs?
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

TPM

Introduction

Brief History of TPM

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
TPM

Why is TPM Important?

TPM

Why is TPM Important

TPM

Why is TPM Important

TPM

Why is TPM Important Benefits

WHY???
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
TPM

Why is TPM Important Benefits

WHY??? To reduce Waste?

Equipment Breakdowns
Setup and Adjustment Delays
Idling and minor stoppages
Reduced Speed
Process Defects
Reduced Yield

TPM

Typical Maintenance Strategies

TPM

Typical Maintenance Strategies

Types

Reactive
Preventive
Predictive
Corrective Maintenance
Maintenance Elimination

All of these can have a place, yet some

better than others

TPM

Typical Maintenance Strategies

Most Common Strategy?

If it aint broke,
dont fix it.

Reactive Maintenance

TPM

Typical Maintenance Strategies

Reactive Maintenance = 55%

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.

TPM

Typical Maintenance Strategies

Can we get better?

Time or
Machine
cycle based
maintenance
functions

Preventive Maintenance
TPM

Typical Maintenance Strategies

Preventive Maintenance = 31%

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.
TPM

Typical Maintenance Strategies

Anything Better?

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

Predictive Maintenance
TPM

Typical Maintenance Strategies

Predictive Maintenance = 12%

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.
TPM

Typical Maintenance Strategies

More?

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

Corrective Maintenance
TPM

Typical Maintenance Strategies

More?

Removing or
reducing the
need for
maintenance to
occur

Maintenance Elimination
TPM

What Does TPM Look Like?

TPM

What Does TPM Look Like?

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

TPM

What Does TPM Look Like?

TPM Implemented?
Tools necessary are readily available

TPM

What Does TPM Look Like?

TPM Implemented?
Equipment modified such that easy to keep clean,
easy to see when maintenance is required.

Befor
e

After

TPM

What Does TPM Look Like?

TPM Implemented?
More examples of easily cleaned and seen

FilteredAir

Befor
e
After
TPM

What Does TPM Look Like?

TPM Implemented?
More examples of easily cleaned and seen

Befor
e

After

TPM

What Does TPM Look Like?

TPM Implemented?
Equipment modified such that easy to maintain

TPM

How to Implement?

TPM

How To Implement?

How To.
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

TPM

How To Implement? | Equipment Selection

How To.
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

TPM

How To Implement? | Equipment Selection

How To.
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

TPM

How To Implement? | Equipment Selection

How To.
3. Defining Machine Operator Tasks
Develop Standards and Checklists
Cleaning
Lubrication
Visual Checks
Procedures to keep equipment as new

TPM

How To Implement? | Equipment Selection

How To.
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

TPM

How To Implement? | Equipment Selection

How To.
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
TPM

How To Implement? | Equipment Selection

How To.
3. Defining Machine Operator Tasks (cont.)
Implement Daily Operator Activities
Review checklists with operators
Ensure operator training is complete
Finalize checklist schedules

TPM

How To Implement? | Equipment Selection

How To.
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

TPM

How To Implement? | Equipment Selection

How To.
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

TPM

How To Implement? | Equipment Selection

How To.
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
TPM
Lease equipment to ensure usability before

Sustain

TPM

Sustain

Sustaining.
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

TPM

Summary

TPM

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

TPM

Q&A

TPM