Introduction to TPM Objectives and Benefits

September 29, 2008

2008 Productivity Inc. All Rights Reserved

Autonomous Maintenance

Maintenance Process Improvement

TPM

Systematic Equipment Improvement

The Five Pillars of TPM

Training & Skill Development

Cross-Functional, Team-Based Improvement Activities

Early Equipment Management

Textbook Definition
TPM is a plant improvement methodology which enables continuous and rapid improvement through use of employee involvement, employee empowerment, and closed-loop measurement of results.

2008 Productivity Inc. All Rights Reserved

TPM Implementation Nakajimas 12 Steps

Announce Top Managements Decision to Introduce TPM Launch Educational Campaign Create Organizations to Promote TPM Establish Basic TPM Policies and Goals Formulate a Master Plan for TPM Development Hold TPM Kickoff Improve Equipment Effectiveness Establish an Autonomous Maintenance Program for Operators Set-up a Scheduled Maintenance Program for the Maintenance Department 10. Conduct Training to Improve Operation and Maintenance Skills 11. Develop Initial Equipment Management Program 12. Implement TPM Fully and Aim for Higher Goals 1. 2. 3. 4. 5. 6. 7. 8. 9.

2008 Productivity Inc. All Rights Reserved

Characteristics of TPM
Optimum relationships between people and equipment/process Involvement of everyone, from top leadership to shopfloor workers A cross-functional approach, involving all departments Implementation through small group teamwork DATA DRIVEN!!!

2008 Productivity Inc. All Rights Reserved

Two Types of Teams

Manager Manager

Natural team

Natural team

Cross-functional

2008 Productivity Inc. All Rights Reserved

Definition(s)
Note: The DREADED M word is not used!!! So what does maintenance mean anyway Maintenance = The act of maintaining Maintain = To keep in a state of order. To keep in due (rightful, proper, fitting) condition, operation, or force; keep unimpaired.

Definition(s) cont
Fix and Repair = Maintenance HOZEN (Maintenance in Japanese) = Maintaining and preserving perfection through Asset Management. TPM = Total Productive Management TPM = Total Productive Manufacturing

2008 Productivity Inc. All Rights Reserved

TPM Goals
Zero accidents Minimum life cycle cost Zero unplanned downtime Zero speed losses Zero defects

Zero waste!
2008 Productivity Inc. All Rights Reserved

Results
Overall Equipment Effectiveness (OEE) Improved Mean Time Between Failure Improved Mean Time To Repair Improved Etc

2008 Productivity Inc. All Rights Reserved

Actual GREEN Results

$60K/ Month Facilities Maintenance Savings $700K Annual Savings Other-than-hazardous-waste
TPM Process applied to facilities maintenance activities
Plant Air System Plant Lighting during peak Kilowatt usage Plant Start-up/Shut-down Procedures Waste Water Treatment System

Note: Above results since 1998

2008 Productivity Inc. All Rights Reserved

2008 Productivity Inc. All Rights Reserved

TPM Is a Paradigm Shift Old Attitude Old Attitude

I operate, you fix I operate, you fix I fix, you design I fix, you design I design, you I design, you operate operate TPM Attitude TPM Attitude
We are all responsible We are all responsible for our equipment, for our equipment, our plant, and our plant, and our future our future

2008 Productivity Inc. All Rights Reserved

Training and Skill Development

2008 Productivity Inc. All Rights Reserved

Why Training and Skill Development

Operators and Maintenance:
Should possess the training and skills necessary to carry out all of the required TPM activities so that they have
A clear understanding of the criteria for judging normal and abnormal conditions Can be empowered to strictly enforce condition management rules The ability to quickly respond to any and all abnormalities
2008 Productivity Inc. All Rights Reserved

Early Equipment Management (EEM) and Maintenance Prevention (MP) Design

2008 Productivity Inc. All Rights Reserved

EEM and MP Design

EEM and MP Design are two methods of making improvements at the earliest possible stage, with the goal of fix and repair and defect free equipment. In other words Operator/Maintenance friendly equipment through lessons learned on existing equipment and applied to new equipment during the concept, design, and installation phase(s).

2008 Productivity Inc. All Rights Reserved

EEM/MP Design Involvement

EEM/MP Design is a team approach. The team should ALWAYS include members from Maintenance (hourly) Production (hourly) Engineering/Technical

2008 Productivity Inc. All Rights Reserved

Maintenance Process Improvement (MPI)

(Planned, Scheduled Maintenance System)

2008 Productivity Inc. All Rights Reserved

MPI Tools and Activities

Well trained/skilled craftspeople Lubrication Management Preventive Maintenance system Predictive Technologies Documentation Management EEM/MP Design Involvement Maintenance Management System Spare Parts Management
2008 Productivity Inc. All Rights Reserved

The Maintenance Techniques

Preventive Maintenance preventing breakdowns Corrective Maintenance improving or modifying equipment to prevent breakdowns or to make maintenance easier Maintenance Prevention designing and installing equipment that needs little or no maintenance Breakdown Maintenance repairing or fixing after breakdowns occur

2008 Productivity Inc. All Rights Reserved

2008 Productivity Inc. All Rights Reserved

2008 Productivity Inc. All Rights Reserved

2008 Productivity Inc. All Rights Reserved

Systematic Equipment Improvement

(Improve Equipment Effectiveness)

2008 Productivity Inc. All Rights Reserved

SEI
A systematic approach to eliminate waste through analysis of the 6 major losses utilizing cross-functional teams to continuously investigate, test, and implement improvements with a goal of maximizing equipment effectiveness.

DATA DRIVEN PROCESS!!!

2008 Productivity Inc. All Rights Reserved

Six Major Losses to Equipment Effectiveness

Failures Setup/changeover and adjustments Idling and minor stoppages Reduced speed Defects and rework Startup loss

2008 Productivity Inc. All Rights Reserved

How the Losses Reduce Effectiveness

Overall Equipment Effectiveness

Availability Equipment Failures

Perf. Efficiency Reduced Speed

Quality Rejects and Defects Startup Losses

6 Major Losses

Adjustments and Set-Ups

Minor Stops and Idling

2008 Productivity Inc. All Rights Reserved

Autonomous Maintenance

2008 Productivity Inc. All Rights Reserved

What Is Autonomous Maintenance?

A collaborative team activity involving production, maintenance, and engineering An approach that
develops operating and maintenance skills strengthens communication and cooperation

A series of activities implemented in well-defined developmental steps

2008 Productivity Inc. All Rights Reserved

Seven Steps of Autonomous Maintenance

1. Conduct initial cleaning/inspection 2. Eliminate sources of contamination 3. Establish provisional standards 4. Develop general inspection training 5. Conduct general inspections 6. Improve workplace management and control 7. Participate in advanced improvement activities

2008 Productivity Inc. All Rights Reserved

Cross-Functional Team Activity

2008 Productivity Inc. All Rights Reserved

2008 Productivity Inc. All Rights Reserved

2008 Productivity Inc. All Rights Reserved

2008 Productivity Inc. All Rights Reserved

2008 Productivity Inc. All Rights Reserved

2008 Productivity Inc. All Rights Reserved

2008 Productivity Inc. All Rights Reserved

2008 Productivity Inc. All Rights Reserved

2008 Productivity Inc. All Rights Reserved

2008 Productivity Inc. All Rights Reserved

2008 Productivity Inc. All Rights Reserved

2008 Productivity Inc. All Rights Reserved

Zero Breakdown Strategies

Restore equipment Maintain basic equipment conditions Adhere to standard operating procedures Improve operator maintenance skills Dont stop at emergency fixes Correct design weaknesses Study breakdowns relentlessly

2008 Productivity Inc. All Rights Reserved

Button-pushers to Process Owners Firefighters to Maintainers

2008 Productivity Inc. All Rights Reserved