Guide to Implementing Total Productive Maintenance (TPM

12/3/2021
Hamed.Ali.Mohamed2@gmail.com 1

❖ Introduction To TPM
❖ Benefits of TPM
❖ What does TPM look like?
❖ How to implement TPM
❖ How to Sustain TPM
❖ Summary
❖ Questions
TPM
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TPM
The 7 Wastes
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❖ TPM stands for Total Productive Maintenance.
❖ TPM Development was first published in Japan in 1982. Since then new
concepts and refinements have been added to the basic program.
❖ TPM first took root in the automotive industry. More recently it has been
introduced in consumer goods, electronics, plastics and many others.
❖ Administrative and support departments such as product development
and sales also use TPM.
❖ Production output and rate, quality, safety, and the environment depend
almost entirely on the state of equipment.
❖ TPM is a method for continuously improving the effectiveness of
production equipment and processes.
TPM
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TPM
World Class Operating Excellence is Achieved using optimized work standards with
group activities of associates who demonstrate ownership
5S & Teams
Safety Quality Cost Productivity People
Focused
Improvement
Autonomous
Maintenance
Logistics
Office
Quality
Management
Training
&
Development
Early
Equipment
Management
Planned
Maintenance
Environment,
Health
&
Safety
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TPM
❖ Guarantees Significant Tangible Results - Results achieved include –
reduction in equipment breakdowns, lower quality defects and claims,
higher productivity, shrinking inventory, lower number of accidents.
P… net productivity up by 2x
Q…process defect rate down 90%
C…productioncosts down 30%
D…productionand work in process inventories halved
S…accidents 0
M…improvement suggestions up by 10x
❖ Transforms the Plant Environment – a rusty plant can be reborn as a
pleasant, saffe working environment.
❖ Transforms the Employees - As concrete results are achieved, workers
become motivated. Associates begin to think of TPM as part of their
job.
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Benefits of TPM
TPM
❖ Customers and visitors are impressed by these changes
❖ Confidence in the plant’s products increases.
❖ Overall Equipment Effectiveness (OEE) is maximized through
zero breakdowns and failures, zero accidents, zero defects
through total employee involvement.
❖ Equipment reliability and maintainability as contributors to
quality and productivity is increased.
❖ TPM culture promotes zero loss activities.
❖ TPM involves all associates from the shop floor to top
management.
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Benefits of TPM
TPM
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TPM
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What Does TPM Look Like?
TPM
❖ Machine Operators are trained to do much of the maintenance
operations, and it’s part of their Standard Work
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TPM
❖ Necessary tools are readily available
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TPM
❖ Equipment is modified such that it easy to keep clean, easy
to see when maintenance is required.
Before After
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TPM
❖ Happy and Engaged Associates……
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How To Implement TPM?
TPM
1. Formally announce decision to introduce TPM.
2. Conduct TPM introductory education & publicity campaign
3. Create a TPM promotion organization.
Plant Manager
Section Managers
Group Leaders
Shop FloorAssociates
Companywide TPM promotion
Committee
Plant TPM Promotion
Committee
Section TPM Promotion
Committee
PM circles
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TPM
Policy – example:
▪ Establish a profitable corporate constitution, promote TPM
Establish numerical goals – examples:
▪ Zero breakdowns,
▪ Zero defects, seek to maximize overall equipment effectiveness.
4. Establish basic TPM policy and goals.
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TPM
5. Draft a master plan for implementing TPM.
To formulate a master plan for implementation decide what
activities must be pursued to achieve the TPM goals.
The core TPM activities are:
▪ Focused improvement
▪ Autonomous Maintenance
▪ Planned Maintenance
▪ Education and Training
▪ Early Equipment Management
▪ Quality Maintenance
▪ Administrative and support department activities (Logistics & Office)
6. Kick off TPM initiative – should be designed to cultivate an atmosphere
that raises morale and inspires dedication.
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TPM
7. Build a corporate constitution designed to maximize production
effectiveness.
8. Build an early management system for new products and
equipment.
9. Build a quality maintenance system.
10. Build an effective administration and support system.
11. Develop a system for managing health, safety, and the
environment.
12. Sustain full TPM implementation and sustain levels.
The first pillars to implement are the Focused Improvement, Autonomous
Maintenance, Planned Maintenance, & Training and Development
Pillars
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TPM
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TPM
The Eight Major Plant Losses:
❖ Shutdown loss
❖ Production adjustment loss
❖ Equipment failure loss
❖ Process failure loss
❖ Normal production loss
❖ Abnormal production loss
❖ Quality defect loss
❖ Reprocessing loss
Loss deployment
◦ All pillars are responsible
for analyzing the loss
deployments for their
losses.
◦ As losses are reduced,
the priority of teams
selected will change
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TPM
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How To Implement TPM? |
TPM
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TPM
1. Select Equipmentto work on….
• Equipment that is giving you problems with…
• Unplanned downtime
• Excessive quality problems
• Excessive repair costs
• Premature “end of life” failures
• Running slower than “design” to prevent breakdowns
2. 5S Event….
• Improve ability to perform regular inspections
• Allow the discovery of potential problems
• Log problems and potential problems and develop an
immediate action plan
• Mark all lubrication, fluid connections and directions, etc
• Paint equipment
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TPM
3. Defining Machine Operator Tasks
• Develop Standards and Checklists – Cleaning,
Lubrication, Visual Checks, Procedures to keep
equipment new.
4. Make Machne Operator maintenance tasks easier/quicker
• Easy to see when things need to be maintained
• Lubrication needs become obvious to operator
• Routine cleaning operations easier
• Machine disassembly minimized
• Automate maintenance when possible
• Clear signals when maintenance is needed
• Ensure operator training is complete
• Finalize Checklist schedules
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TPM
Define Maintenance Tech Tasks
• Provide Tech support to operator questions
• Provide clear communication path
• Spare Parts Program
• Equip Manufacturer recommendations
• Breakdown History Data
• Eliminate Equipment Deterioration
• Scheduled general inspections
• Equipment overhauls triggered by checklists
• Identify and Resolve Chronic Problems
• Breakdown history log
• Root cause analysis methods including 5 Whys
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TPM
Define Maintenance Tech Tasks
• Develop and Analyze Equipment History
• Plot failure history
• Correlate with Equipment Quality Performance
• Determine Equipment Parameters That Predict
Failure
• Use information from equipment manufacturer
• Oil, vibration, temperature analysis
• Develop Equipment Monitoring Systems
• Ensure appropriate accuracy and tolerance
• Lease equipment to ensure usability before
purchase
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TPM
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Benefits of TPM
TPM
❖ Reactive Maintenance – if it is not broken do not fix it.
❖ Preventive Maintenance – time or machine cycle based
maintenance functions
❖ Predictive Maintenance – functions on feedback that
something needs to be done.
❖ TPM – Autonomous Maintenance & Planned Maintenance
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❖ Loss methologies in use:
◦ Use of a QA Matrix which is a tool that prioritizes
actions against the sources of defects in a process.
The matrix correlates defect modes with machine
parameters. The matrix identifies the location of ‘Q’
points – the points that need to be controlled to
eliminate defects.
◦ Defect Reduction Methodology
◦ CpK Improvement Methodology
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How to Sustain TPM?
TPM
❖ Measuring progress is key (through Steering Committee)
❖ The Primary Measurement tool is OEE (Overall Equipment
Effectiveness is measures….
OEE = Equip Availability X Performance Efficiency X Quality Rate
❖ Build strong teams at every level and staff a promotion office
❖ Track projects weekly from date of closure, up to 6 months then
monthly for the next 6 months. When a project looses traction,
the pillar team analyzes the anomaly & take corrective actions as
needed. Once a project is sustained for a year, it can be
removed from the KPI tracker.
❖ Use management indicators that show everyone (at every level)
what concrete progress is being made and motivate their
continued involvement.
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How to Sustain TPM
TPM
❖ Recognized as the Global leaders in TPM
❖ Two audits take place with Japanese auditors
❖ In the face of growing competition, the award drives a continuous
culture of improvement the focuses on cost reduction & improvement
in efficiencies
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Summary
TPM
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❖ TPM is a method for continuously improving the
effectiveness of production equipment and
processes by improving ‘On Demand’ availability of
the equipment, through improved maintenance.
❖ The primary focus is on involving machine
operators in routine maintenance, and making that
maintenance easily seen, easily done, and
effective. This only happens through involvement
of every single associate in every department in a
factory.
Summary
TPM
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Questions
TPM
12/3/2021

Guide to Implementing Total Productive Maintenance (TPM

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