Tpm Sample

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Tpm Sample

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Tpm Sample

  1. 1. Total Productive Maintenance (TPM) Superfactory Manufacturing Excellence Series Lean Overview 5S & Visual Factory Cellular Manufacturing Jidoka Kaizen Poka Yoke & Mistake Proofing Quick Changeover & SMED Production Preparation Process (3P) Pull Manufacturing & Just In Time Standard Work Theory of Constraints Total Productive Maintenance Training Within Industry (TWI) Value Streams
  2. 2. Contents © 2007 Superfactory™. All Rights Reserved. <ul><li>Introduction </li></ul><ul><li>Background and History </li></ul><ul><li>Components and Implementation </li></ul><ul><ul><li>TPM benefits </li></ul></ul><ul><ul><li>Prerequisites </li></ul></ul><ul><ul><li>Types of maintenance strategies </li></ul></ul><ul><ul><li>Implementing TPM </li></ul></ul><ul><ul><li>TPM management </li></ul></ul><ul><ul><li>Maintenance metrics </li></ul></ul><ul><li>Knowledge Check </li></ul>
  3. 3. Introduction © 2007 Superfactory™. All Rights Reserved. <ul><li>TPM is a method for continuously improving the effectiveness of production equipment and processes </li></ul><ul><li>The key difference between TPM and other maintenance programs is that TPM requires the involvement of all people in the organization </li></ul><ul><li>TPM aims to achieve a 100% on-demand equipment availability by eliminating: </li></ul><ul><ul><li>Equipment breakdowns and other unplanned downtime </li></ul></ul><ul><ul><li>Scrap and rework by poor equipment performance </li></ul></ul><ul><ul><li>Reduced productivity due to running at reduced speeds, idling, or stoppages requiring operator attention </li></ul></ul><ul><ul><li>Equipment startup losses </li></ul></ul>
  4. 4. Components and Implementation © 2007 Superfactory™. All Rights Reserved. <ul><li>TPM benefits </li></ul><ul><li>Prerequisites </li></ul><ul><li>Types of maintenance strategies </li></ul><ul><li>Implementing TPM </li></ul><ul><li>TPM management </li></ul><ul><li>Maintenance metrics </li></ul>
  5. 5. Types of Maintenance Strategies © 2007 Superfactory™. All Rights Reserved. <ul><li>Breakdown Maintenance </li></ul><ul><ul><li>Reactive “wait until it breaks” strategy </li></ul></ul><ul><li>Preventative Maintenance </li></ul><ul><ul><li>Traditional scheduled periodic maintenance </li></ul></ul><ul><li>Predictive Maintenance </li></ul><ul><ul><li>Using monitoring equipment coupled with historical data to predict life cycle of components </li></ul></ul>
  6. 6. Types of Maintenance Strategies © 2007 Superfactory™. All Rights Reserved. <ul><li>Corrective Maintenance </li></ul><ul><ul><li>Modification or improvement of equipment based on root cause analysis of failures </li></ul></ul><ul><li>Maintenance Elimination </li></ul><ul><ul><li>Equipment designed to eliminate all forms of maintenance </li></ul></ul>
  7. 7. Implementing TPM © 2007 Superfactory™. All Rights Reserved. <ul><li>Select Facilitator </li></ul><ul><li>Select first TPM area and team </li></ul><ul><li>Develop goals and schedule </li></ul><ul><li>Train team members and operators in autonomous maintenance </li></ul><ul><li>Train maintenance technicians in preventative maintenance </li></ul><ul><li>Train maintenance technicians in predictive maintenance </li></ul>
  8. 8. 2. Select First TPM Area and Team © 2007 Superfactory™. All Rights Reserved. <ul><li>First area must be able to be shut down for several days </li></ul><ul><li>Area where downtime and quality are major problems </li></ul><ul><li>Must have 5S program in place </li></ul><ul><li>Team must have representatives from all shifts </li></ul><ul><li>Team must be able to stay together after the TPM event </li></ul><ul><li>Must include someone familiar with the technology of the equipment </li></ul><ul><li>Include others who are unfamiliar with the equipment to add a “new set of eyes” </li></ul>
  9. 9. TPM Management © 2007 Superfactory™. All Rights Reserved. <ul><li>All activities involved in keeping a system’s equipment working </li></ul><ul><li>Objective: Maintain system capability & minimize total costs </li></ul><ul><li>Failure has far reaching effects on a firm’s </li></ul><ul><ul><li>operation </li></ul></ul><ul><ul><li>reputation </li></ul></ul><ul><ul><li>profitability </li></ul></ul><ul><ul><li>customers </li></ul></ul><ul><ul><li>product </li></ul></ul><ul><ul><li>employees </li></ul></ul><ul><ul><li>profits </li></ul></ul>
  10. 10. Lifetime Failure Rates © 2007 Superfactory™. All Rights Reserved. Infant mortality and improper use failure “ normal” failure Wearout failure Failure rate Lifetime
  11. 11. Maintenance Costs Full Cost View © 2007 Superfactory™. All Rights Reserved. Maintenance Commitment Cost Optimal Total costs Full cost of breakdowns Preventive maintenance costs

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