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TOTAL PRODUCTIVE MAINTENANCE

(TPM)

You cant be Lean if dont have reliable equipments

Qadeer .A. Bhatti Putting Maintenance Techniques To Work For You
M.Sc Engg, PMP, CLSSMBB
 Training Objectives
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Reliability and Failure Types

Maintenance Autonomous
Types of Maintenance
Maintenance Overall
Total Productive Equipment
Maintenance Effectiveness
(TPM) (OEE)
Pillars of TPM TPM Benefits
Understanding CMMS,
Downtime capabilities and
Six Big Losses benefits.
 Orlando Utilities Commission (OUC)
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Maintenance of power generating plants

Every year each plant is taken off-line for 1-3 weeks
maintenance
Every three years each plant is taken off-line for 6-8
weeks for complete overhaul and turbine inspection
Each overhaul has 1,800 tasks and requires 72,000
labor hours
OUC performs over 12,000 maintenance tasks each
year
 Orlando Utilities Commission
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Every day a plant is down costs OUC $110,000

Unexpected outages cost between $350,000 and
$600,000 per day
Preventive maintenance discovered a cracked
rotor blade which could have destroyed a $27
million piece of equipment
 Two Strategies
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Reliability
Improving individual components
Providing redundancy
Maintenance
Implementing or improving preventive maintenance
Increasing repair capability or speed
 Maintenance and Reliability
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Maintenance is a set of organized activities that are carried

out in order to keep the machine in its best operational
condition with minimum cost required.
Reliability is the probability that a machine will function
properly for a specified time.
 Maintenance Management
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Employee Involvement
Partnering with maintenance
personnel
Skill training Results
Reward system
Employee empowerment Reduced inventory
Improved quality
Improved capacity
Reputation for quality
Maintenance and Reliability Continuous improvement
Procedures Reduced variability
Clean and lubricate
Monitor and adjust
Make minor repair
Keep computerized records
 The Maintenance System
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Enterprise System

Feedback
Inputs Outputs

Materials Capacity
Labor Quality
Spares Adjust Availability
Tools Calibrate Reliability
Money Inspect Maintainability
Technology Repair Safety
Information Replace Cost
Facilities
 Strategic Importance of Maintenance and Reliability
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The objective of maintenance and

reliability is to maintain the
capability of the plant or system
 Strategic Importance of Maintenance and Reliability
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Failure has far reaching effects on a firms

Operation
Reputation
Profitability
Dissatisfied customers
Idle employees
Profits becoming losses
Reduced value of investment in plant and equipment
 Types of Maintenance
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 Reactive/Breakdown Maintenance
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This is basically the run it till it breaks maintenance

mode.
This is still the predominant mode of maintenance in the Average Maintenance program
Predictive,
Others,
2%
west including United States. 12%

A recent study in the United States shows breakdown

the average maintenance program.
Preventive Reactive,

>55% Reactive/Corrective
, 31% 55%

Reactive Preventive Predictive Others

31% Preventive

12% Predictive

2% Others
 Reactive/Breakdown Maintenance
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Advantages:
Initial low Cost.
Initial less Staff.
Disadvantages
Increased cost due to unplanned downtime of equipment.
Increased labor cost, especially if overtime is needed.
Extra cost involved with repair or replacement of the equipment.
Possible secondary equipment damage from primary equipment failure.
Inefficient use of staff resources.
 Preventive Maintenance
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Set of actions performed on a time or machine run based

schedule that detect, preclude or mitigate degradation of a
component or system with the aim of sustaining or extending its
useful life through controlling degradation to an acceptable
level.
 Preventive Maintenance
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Advantages:
Cost effective.
Increased component life cycle.

Energy savings.

Reduction in component failures.

Estimated 12% to 18% cost savings over Reactive

maintenance program.
 Preventive Maintenance
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Disadvantages:
Catastrophic failures still likely to occur.
Labor intensive.

Includes performance of some unneeded components.

Potential for incidental damage to component in conduction

unneeded maintenance.
 Predictive Maintenance
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Measurements that detect the onset of a degradation

mechanism, thereby allowing casual stressors to be eliminated or
controlled prior to any significant deterioration in the component
physical state.
Predictive maintenance differs from preventive maintenance by
basing maintenance need on the actual condition of the
machine rather than on some preset schedule.
 Predictive Maintenance
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Advantages
Increased component/machine life/availability.
Allows for preemptive corrective actions.
Decrease in machine/component downtime.
Decrease in cost for parts and labor.
Better product quality.
Improved worker and environmental safety.
Improved employees moral.
Energy savings.
Estimated 8% to 12% cost savings over preventive maintenance
program.
 Predictive Maintenance
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More Advantages*
Return on investment: 10 Times.
Reduction in maintenance costs: 25% to 30%.

Elimination of breakdowns: 70% to 75%.

Reduction in downtime:35% to 45%.

Increase in production: 20% to 25%.

*(O & M Best Practices)

 Predictive Maintenance
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Disadvantages
Increased investment in diagnostic equipments.
Increased investment in staff training.

Savings potential not readily seen by the

management.
 Reliability Centered Maintenance
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A process used to determine the maintenance requirements of any

physical asset in its operating context.
It is based on the fact that:
All equipment in a facility are not of equal importance to either the
process or facility safety.
Equipment design and operation differs.
Some equipments have a higher probability to undergo failures from
different degradation mechanism than others.
It uses a blend of predictive maintenance for expensive and
important equipments and breakdown maintenance for
inexpensive and unimportant equipments.
 Reliability Centered Maintenance
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Advantages
Can be most efficient program.
Lower costs by eliminating unnecessary maintenance or
overhauls.
Minimize frequency of overhauls.
Reduced probability of sudden equipment failures.
Able to focus maintenance activities on critical components.
Increased component reliability.
Incorporates root cause analysis.
 Reliability Centered Maintenance
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Advantages Cont.
Following is the breakdown of Reliability centered
maintenance (RCM) program:
< 10% Reactive
25% to 35% Preventive
45% to 55% Predictive
Disadvantages
Can have significant startup cost, training, equipments etc.
Savings potential not readily seen by the management.
 Maintenance Types Summery
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Maintenance Basic Philosophy Cost

Type $/hp/year
Reactive Allow machinery to run to failure. 18
Preventive Schedule maintenance activities at
predetermined intervals. 13
Predictive Schedule maintenance activities when
mechanical or operational conditions 9
warrant.
Reliability Utilizes preventive/corrective
Centered maintenance techniques with root 6
cause failure analysis.
Source: O&M Guide