Total Productive Maintenance

Comprehensive, life cycle approach

Minimizes equipment failures, production defects and accidents
Involves everyone
A method to achieve maximum equipment effectiveness through employee involvement

Objectives of TPM

Ideal goals: Zero failure, zero defects and zero accidents

Continuously improve availability and prevent degradation

TPM Concepts
Autonomous Maintenance

Equipment operators performing some routine maintenance tasks

Daily cleaning, inspecting, tightening, lubricating
Operators to quickly notice anomalies
Maintenance staff trains operators
Special safety awareness training provided to operators
Implementation includes use of visual controls

Planned Maintenance

Activities scheduled to repair equipments before they breakdown

Production schedule to accommodate planned downtime

Maintenance Reduction

Consists of equipment design and predictive maintenance

Working with equipment suppliers
Maintenance knowledge incorporated into next generation of equipment designs
Equipment manufacturer even includes visual control markings and labels
Special equipment analysis to collect data to predict equipment failure
Thermography, Ultrasound, Vibration analysis

Equipment Effectiveness

Equipment effectiveness is not only equipment availability

Overall equipment effectiveness that also includes equipment efficiency and quality rate

Equipment Availability
Equipment availability = Actual Operating Time/ Net available Run Time

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

Overall Equipment Effectiveness

Overall Equipment Effectiveness = Equipment Availability x Performance Efficiency x
Quality Rate

Ready for maintenance?

Assignment 1: Wednesday, 30th September

2015
Quiz 1: Wednesday, 30th September 2015

Eliminating Process Losses

Losses Due to Downtime

Breakdowns
Proactive replacement during scheduled maintenance

Setup and Adjustment

Internal setup and external setup

Losses Due to Poor Performance

Reduced Speed
Excessive equipment wear
Idling and Minor Stops
Equipment jams

Losses Due to Poor Quality

Process Defects
Improving equipment
Startup Losses
Product waste until operating temperature

Benefits of Total Productive Maintenance

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