Total Productive Maintenance (TPM)

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As a company-wide initiative, Total Productive Maintenance (TPM) maximizes the effectiveness of equipment. The TPM program significantly increases labor and capital productivity while, at the same time, increases employee morale and job satisfaction. TPM brings maintenance into focus as a necessary and vitally important part of the business. Targeted at all levels of the organization, TPM and its 8 Pillars provide the necessary supporting process and tools to achieve zero defects, zero breakdowns and zero accidents.

Specially developed by a JIPM-certified TPM consultant, this professional presentation on Total Productive Maintenance combines the TPM tools, 5S, OEE (Overall Equipment Effectiveness), 8 pillars, Autonomous and Planned maintenance into a highly detailed training tool. This PowerPoint includes a step-by-step implementation process of TPM.

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Total Productive Maintenance (TPM)

  1. 1. 1© Operational Excellence Consulting. All rights reserved. Total Productive Maintenance (TPM) Total Productive Maintenance (TPM) © Operational Excellence Consulting. All rights reserved.
  2. 2. 4© Operational Excellence Consulting. All rights reserved. Program Outline 1. Overview of TPM 2. TPM Foundations: 5S & Visual Management 3. TPM Tools 4. Equipment Loss & OEE 5. 8 Pillars of TPM 6. Key Pillars of TPM - Autonomous Maintenance - Planned Maintenance - Focused Improvement - Education & Training 7. Other TPM Pillars 8. TPM Implementation 9. Critical Success Factors This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  3. 3. 7© Operational Excellence Consulting. All rights reserved. Productive Maintenance (“Profitable PM”) Productive Maintenance (“Profitable PM”) Preventive Maintenance Breakdown Maintenance Corrective Maintenance Maintenance Prevention Preventing breakdowns Designing and installing equipment that needs little or no maintenance Improving or modifying equipment to prevent breakdowns or to make maintenance easier Repairing after breakdowns occur This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  4. 4. 10© Operational Excellence Consulting. All rights reserved. Maintenance Prevention • Designing or specifying equipment that doesn’t break down and easy to maintain • Studying of maintenance data and developing “maintenance-free” designs for equipment that doesn’t breakdown, safe and easy to use • For MP to succeed, operators and maintenance people need to collect data This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  5. 5. 13© Operational Excellence Consulting. All rights reserved. Machine Failures Have Many Hidden Causes Less Visible Visible Failure Loosening Contamination CorrosionLeaks FlawsDeformation VibrationCracks BacklashImproper Temperature Wear Failure is what we see but is only the tip of the iceberg Failure is what we see but is only the tip of the iceberg Minor machine defects are generally unnoticed but are the cause of almost all machine failures Minor machine defects are generally unnoticed but are the cause of almost all machine failures This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  6. 6. 16© Operational Excellence Consulting. All rights reserved. TPM is a Paradigm Shift Maintenance Operator Maintenance Old Attitude TPM Attitude I use I maintain & I fix We maintain Operator This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  7. 7. 19© Operational Excellence Consulting. All rights reserved. Why TPM? • Avoid wastage in a quickly changing economic environment • Producing goods without reducing product quality • Produce a low batch quantity at the earliest possible time • Reduce cost • Goods delivered to customers must be non-defective This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  8. 8. 22© Operational Excellence Consulting. All rights reserved. TPM Pillars & Activities 1 Pillar Activities Focused equipment and process improvement Measure of equipment- or process-related losses and specific improvement activities to reduce the losses Autonomous maintenance Operator involvement in regular cleaning, inspection, lubrication, and learning about equipment to maintain basic conditions and spot signs of trouble Planned maintenance A combination of preventive, predictive, and proactive maintenance to avoid losses, and planned responses to fix breakdowns quickly Quality maintenance Activities to manage product quality by maintaining optimal operating conditions This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  9. 9. 25© Operational Excellence Consulting. All rights reserved. How TPM Benefited Kodak • Increased uptime, fewer breakdowns and longer-lasting parts • Significant reduction in unit manufacturing cost • Reduction in Maintenance overtime by 10% • Maintenance costs dropped to below budget allocation • Employee absenteeism fell from 3% to less than 2% within 2 years • Significant improvement in maintenance customer satisfaction • Reduction in spare parts inventory • Reduction in MTTR • Reduction in backlog • Two-third reduction in the annual cost of cutting blades Source: TPM – Collected Practices & Cases, Productivity Press, 2005 This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  10. 10. 28© Operational Excellence Consulting. All rights reserved. Meaning of 5S Principles General Description 1S Sort Remove what is not needed and keep what is needed 2S Set in Order Arrange essential items in order for easy access 3S Shine Keep things clean and tidy; no trash or dirt in the workplace 4S Standardize Establish standards and guidelines to maintain a clean workplace 5S Sustain Make 5S a habit and teach others to adhere to established standards This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  11. 11. 31© Operational Excellence Consulting. All rights reserved. 1S : Sort • The first step in 5S is to get rid of what we do not need • Go through all the tools, equipment, materials, etc. in the plant and work areas Keep only essential items Everything else is stored away or discardedThis document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  12. 12. 34© Operational Excellence Consulting. All rights reserved. 2S : Set In Order - Examples This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  13. 13. 37© Operational Excellence Consulting. All rights reserved. 3S : Shine – Practice Tips 1 • Obtain appropriate tools and supplies for cleaning • Increase the lighting in the work area • Divide the area into zones • Define responsibilities for cleaning • Repair any leaks on equipment • Provide protection for the persons doing the cleaning • Clean machines, floors, walls and ceilings This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  14. 14. 40© Operational Excellence Consulting. All rights reserved. 4S : Standardize – Practice Tips 1 • Define work instructions and procedures • Make standards to detect abnormality • Implement poka-yoke (error proofing) systems • Train employees to follow established standards and guidelines Cleaning, inspection and lubrication • Train new employees on the 5S system. Develop training documentation for this purpose.This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  15. 15. 43© Operational Excellence Consulting. All rights reserved. How to Sustain 5S? • Get management commitment • Get everyone involved • Get authorization from management for 5S activities • Promote 5S in the organization • Do it all the way • Gemba walk by CEO • Conduct monthly review by 5S committee • Use 5S as a platform to launch other continuous improvement programs/initiatives This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  16. 16. 46© Operational Excellence Consulting. All rights reserved. Visual Controls • The name given to a whole range of activities for communicating and controlling what needs to be done • 5S can be enhanced by the use of visual controls • Use visual controls to help you monitor results and look for things easily and quickly Note: Visual management IS NOT decoration Note: Visual management IS NOT decoration This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  17. 17. 49© Operational Excellence Consulting. All rights reserved. Warning Sensors • Warning sensors signal the operator that there is a problem. These sensors use colors, alarms, lights to get the workers attention! • These sensors may be used in conjunction with a contact or energy sensor to get the operators attention. Color Code Lights Lights connected to Micro switches & timers This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  18. 18. © Operational Excellence Consulting. All rights reserved. Session 3: Key Tools for TPM This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  19. 19. This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  20. 20. 58© Operational Excellence Consulting. All rights reserved. Fuguai Tagging (F-Tag) • Fuguai Tags are attached to equipment where problems are discovered • Two categories of Fuguai Tags: Blue Tag – repairs can be made by operator Red Tag – repairs by maintenance staff • Fuguai Register A log for all Fuguai’s issued and resolved This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  21. 21. 61© Operational Excellence Consulting. All rights reserved. What is One-Point Lesson? • One-point lesson is a 5-10 min self-study lesson drawn up by team members • Lesson covers a single aspect of equipment or machine structure, functioning or inspection method • Is a highly effective tool because it is short and focused on a topic This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  22. 22. 64© Operational Excellence Consulting. All rights reserved. Example: One-Point Lesson Source: DIYLean.com This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  23. 23. 67© Operational Excellence Consulting. All rights reserved. Board is filled by hand. Checklists (beside board) are also made manually. Example: 5S Activity Board This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  24. 24. This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  25. 25. 73© Operational Excellence Consulting. All rights reserved. Overall Equipment Effectiveness (OEE) 2 Overall Equipment Effectiveness = Availability x Performance x Quality Availability = Operating Time / Planned Production Time Performance = (Ideal Cycle Time x Total Pieces) / Operating Time Quality = Good Pieces / Total Pieces Simplest OEE Formula: OEE = (Good Pieces x Ideal Cycle Time) / Planned Production Time Where: • Good Pieces (pieces that are manufactured without any defects) • Ideal Cycle Time (the theoretical fastest possible time to manufacture one piece) • Planned Production Time (the total time that the production asset is scheduled for production) • Fully Productive Time (producing only good pieces, as fast as possible, with no down time) This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  26. 26. 76© Operational Excellence Consulting. All rights reserved. Eight Major Pillars of TPM The eight pillars of TPM are mostly focused on proactive and preventative techniques for improving equipment reliability. TPMintheOffice Safety&Environmental Management AutonomousMaintenance PlannedMaintenance FocusedImprovement EarlyEquipment Management QualityMaintenance Education&Training 5S & Visual Management TPM Goals: Zero Defects, Zero Breakdowns, Zero Accidents This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  27. 27. 79© Operational Excellence Consulting. All rights reserved. Autonomous Maintenance • Benefits: Gives operators greater “ownership” of their equipment Increases operators’ knowledge of their equipment Ensures equipment is well-cleaned and lubricated Identifies emergent issues before they become failures Frees maintenance personnel for higher-level tasks Objective: To place responsibility for routine maintenance, such as cleaning, lubricating, and inspection, in the hands of operators This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  28. 28. 82© Operational Excellence Consulting. All rights reserved. Natural & Forced Deterioration • Deterioration is what leads equipment to break down or generate defective parts • Natural Deterioration – Normal wear caused by parts rubbing against one another • Forced Deterioration – Deterioration that happens sooner than it would naturally. Usually caused by our failure to do something we ought to. Examples: Not keeping parts clean and lubricated Ignoring excessive loads in moving partsThis document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  29. 29. 85© Operational Excellence Consulting. All rights reserved. Example 2: Autonomous Maintenance Source: Nippon Denso Color-coded lubrication container station ensures the right lubricant is applied to the right equipment This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  30. 30. 88© Operational Excellence Consulting. All rights reserved. 7 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 continuous improvement activities This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  31. 31. 91© Operational Excellence Consulting. All rights reserved. Planned Maintenance • Benefits Significantly reduces instances of unplanned down time Enables most maintenance to be planned for times when equipment is not scheduled for production Reduces inventory through better control of wear- prone and failure-prone parts Objective: To increase equipment reliability and minimize maintenance cost by reducing breakdowns and developing efficient maintenance methods This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  32. 32. 94© Operational Excellence Consulting. All rights reserved. Planned Maintenance • How to achieve the natural life cycle of individual machine elements Correct operation Correct set-up Cleaning Lubrication Retightening Feedback and repair of minor defects Quality spare partsThis document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  33. 33. 97© Operational Excellence Consulting. All rights reserved. Identifying a Complete Machine Preventive Maintenance Plan • A complete scheduled maintenance plan consists of seven elements: 1. PM checklist 2. PM schedules 3. Inspection specifications 4. Replacement part numbers 5. PM procedures 6. Part logs 7. Quality checks This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  34. 34. 100© Operational Excellence Consulting. All rights reserved. Planned Maintenance – Practice Tips 2 • Do not use equipment failure to schedule maintenance work. This is breakdown – not preventive – maintenance. • Attempt to develop a maintenance plan for each component. Redesign machine only if an acceptable maintenance plan cannot be developed. This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  35. 35. © Operational Excellence Consulting. All rights reserved. Session 7: Focused Improvement This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  36. 36. 106© Operational Excellence Consulting. All rights reserved. Focused Improvement • Benefits Recurring problems are identified and resolved by cross-functional teams Combines the collective talents of a company to create an engine for continuous improvement Objective: To achieve regular, incremental improvements in equipment operation by small groups of employees working together proactively so as to continually improve OEE performance This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  37. 37. 109© Operational Excellence Consulting. All rights reserved. Focused Improvement – Factors Affecting Product Quality Product defect is affected by the 4Ms: • Machines: equipment function and precision • Men (people): level of human skills, behaviors and adherence to standards • Materials: quality of incoming parts or materials • Methods: appropriateness of operating and inspection methods and standardsThis document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  38. 38. 112© Operational Excellence Consulting. All rights reserved. Kaizen Toolbox for TPM Problem Solving • Where - Where analysis • Why - Why analysis • Fishbone diagram • 5W1H • Pareto chart • Flow charts • Check Sheet • Graph/Control chart • Histogram • Scatter Diagram • Brainstorming This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  39. 39. 115© Operational Excellence Consulting. All rights reserved. No/Low Cost Solution: One-Motion Methods Cam Method Quick Changeover Wing Nut Method Pear-Shaped Hole Method Tighten Here Attach and Remove Here This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  40. 40. 118© Operational Excellence Consulting. All rights reserved. Quality Maintenance • Quality rate has a direct correlation with: Material conditions Equipment precision Production methods Process parameters This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  41. 41. 121© Operational Excellence Consulting. All rights reserved. Quality Maintenance – Basic Principles 1. Set standards for distinguishing normal and abnormal states 2. Strictly follow all the standards and rules that have decided on 3. Discover any abnormalities in the equipment that may cause defects 4. Immediately begin the proper treatment for any abnormalitiesThis document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  42. 42. 124© Operational Excellence Consulting. All rights reserved. Perspectives of Equipment Weak Points • The search for weak points in equipment can be carried out from the following perspectives: Facilitating Autonomous Maintenance Increasing Ease of Operation Improving Quality Improving Maintainability Safety This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  43. 43. 127© Operational Excellence Consulting. All rights reserved. Education and Training • Benefits Operators develop skills to routinely maintain equipment and identify emerging problems Maintenance personnel learn techniques for proactive and preventative maintenance Managers are trained on TPM principles as well as on employee coaching and development Objective: To enhance employees’ skills in TPM methodology and fill in knowledge gaps necessary to achieve TPM goals This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  44. 44. 130© Operational Excellence Consulting. All rights reserved. Education and Training • The different phases of skills are: Phase 1 : Do not know Phase 2 : Know the theory but cannot do Phase 3 : Can do but cannot teach Phase 4 : Can do and also teach This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  45. 45. 133© Operational Excellence Consulting. All rights reserved. TPM in the Office • Office TPM should be started after activating four other pillars of TPM (AM, FI, PM, T&E) • Office TPM must be followed to improve productivity, efficiency in the administrative functions and identify and eliminate losses • This includes analyzing processes and procedures towards increased office automation This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  46. 46. 136© Operational Excellence Consulting. All rights reserved. Focused Improvement Topics for Office TPM • Inventory reduction • Lead time reduction of critical processes • Motion and space losses • Retrieval time reduction • Equalizing the work load • Improving the office efficiency by eliminating the time loss on retrieval of information, by achieving zero breakdown of office equipment like telephone and fax lines This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  47. 47. 139© Operational Excellence Consulting. All rights reserved. Safety & Environmental Management • Focus is to create a safe workplace and a surrounding area that is not damaged by our process or procedures • This pillar will play an active role in each of the other pillars on a regular basis • To create awareness among employees various competitions like safety slogans, quiz, posters, etc. related to safety can be organized at regular intervals • Alignment to ISO 14001 and ISO 18001 standardsThis document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  48. 48. © Operational Excellence Consulting. All rights reserved. Session 9: TPM Implementation This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  49. 49. 145© Operational Excellence Consulting. All rights reserved. Roles of Pillar Champion • Roles To Lead and Facilitate the TPM Activities for their Pillar Accountable for Pillar results and progress Train and Schedule TPM Steps Form Pillar Committee Present progress to Steering Committee Activity Board – using PDCA cycle • Membership and Frequency Weekly Core Members – Pillar Champions, Committee members Review results Plan Next Steps This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  50. 50. 148© Operational Excellence Consulting. All rights reserved. TPM Implementation: 2. Introductory Education Campaign • Training for different target audiences Awareness vs. intensive • Seminars for managers • “TPM 101” briefings - Slide presentations for all employees • Visit sites/organizations with good TPM practices This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  51. 51. 151© Operational Excellence Consulting. All rights reserved. TPM Implementation: 5. Preparation and Formulation of a Master Plan • A master plan lays out your goals, what you will do to achieve them and when you will achieve them • Detailed plans for each pillar have to be prepared • Managed as one program This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  52. 52. 154© Operational Excellence Consulting. All rights reserved. TPM Implementation: 7. Develop an Equipment Management Program (2) • Typical membership of a team Five to seven operators A maintenance person A technical expert • Tools Pareto chart Cause & effect Root cause Methods analysis This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  53. 53. 157© Operational Excellence Consulting. All rights reserved. TPM Implementation: 10. Increase Skills of Production and Maintenance Personnel • The training sessions must be planned shortly after the kick-off presentation • 2 major components Soft skills training Technical training • Train leaders together • Have leaders share information with group members This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  54. 54. 160© Operational Excellence Consulting. All rights reserved. TPM Implementation: 12. Perfect TPM Implementation and Raise TPM Levels • Evaluate for the PM Award: The Japanese Institute for Productive Maintenance (JIPM) runs the annual PM Excellence Award. They provide a checklist for companies applying for the award. • Set higher goals • Annual TPM site competition • President’s TPM Award TPM Pillar Award This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  55. 55. 163© Operational Excellence Consulting. All rights reserved. How to Sustain TPM • Engaging employees • Aim for early success • Providing active leadership • Share success stories • Rewards and recognition • Continuously improve OEE • Evolving the TPM initiative over timeThis document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
  56. 56. 166© Operational Excellence Consulting. All rights reserved. Copyrights of all the pictures used in this presentation are held by their respective owners. This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/total-productive-maintenance-tpm-158
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