total productive maintanance , meeting agenda , unplanned downtime losses , reduced speed losses , what is total productive maintenance? , breakdown of tpm , tpm - history , goals of tpm , launching tpm- preparatory stage , what is oee , calculating oee , tpm - benefit

1. Meeting Agenda Cont.
I. TPM-8 Pillars-Laura Dietrich
II. Kick off TPM
I. Launching TPM- Preparatory Stage-Antoinette Lockett
II. Autonomous Maintenance- Xiaoyan Liu
III. Equipment Management Life Cycle- Xiaoyan Liu
IV. TPM Implementation-Waseem Manzoor
V. Launching TPM- Stabilization-Waseen Manzoor
VI. Eliminating Equipment Losses-Laura Dietrich
VII. Improvement Goals for Chronic Losses-Laura Dietrich
III. Overall Equipment Efficiency
I. What is OEE-Xiaoyan Liu
II. OEE Factors-Xiayon Liu
III. Calculating OEE-Waseem Manzoor
IV. TPM Benefits-Xiaoyan Liu

2. MAJOR LOSSES

3. Planned Downtime losses
 Start-ups
 shift changes
 coffee and lunch breaks
 planned maintenance shutdowns

4. Unplanned Downtime Losses
Equipment breakdown
Changeovers
Lack of material

5. Reduced Speed Losses
Idling and minor stoppages
Slow-downs

6. Poor Quality Losses
 Process non-conformities
 Scrap

7. TPM

8. What is Total Productive Maintenance?
 TPM is a plant improvement methodology which enables
continuous and rapid improvement of the manufacturing
process through use of employee involvement, employee
empowerment, and closed-loop measurement of results

9. Breakdown of TPM
 TOTAL = All encompassing by maintenance and production individuals
working together
 PRODUCTIVE = Production goods and services that meet or exceed
customers’ expectations
 MAINTENANCE = Keeping equipment and plant in as good as or
better than the original conditions at all times

10. TPM - History
Productive maintenance (PM) originated in
the U.S. in late 1940’s & early 1950’s
Japanese companies modified and enhanced
it to fit the Japanese industrial environment
The first use the term TPM was in 1961 by
Nippondenso, a Japanese auto components
manufacturer
Seiichi Nakajima – head of JIPM, one of the
earliest proponents, known as the Father of
TPM

11. TPM - Evolution
 Breakdown maintenance
 Preventive maintenance (PM)
 Productive maintenance
 Total productive maintenance

13. Goals of TPM
1. Aims at getting the most effective use of
equipment
2. Builds a comprehensive PM system
3. Brings together people from all departments
concerned with equipment
4. Requires the support and cooperation of
everyone from top managers down
5. Promotes and implements PM activities based
on autonomous small group activities.
6. Maintaining Equipment for life
7. Encouraging input from all employees
8. Using teams for continuous improvement

14. Three Principles of Prevention
Maintenance of normal conditions
Early discovery of abnormalities
Prompt response

15. TPM 8 PILLARS

16. PILLARS OF TPM
KobetsuKaizen
PlannedMaintenance
QualityMaintenance
Training
OfficeTPM
Safety,healthand
Environment
5s
AutonomousMaintenance

17. Kick off TPM

18. Launching TPM- Preparatory Stage
 Announce top management’s decision to introduce TPM
 Launch an educational campaign to introduce TPM
 Create an organizational structure to promote TPM
 Establish basic policies
 Form a master plan for implementing TPM

23. Launching TPM- Preliminary
Implementation

24. Launching TPM- TPM Implementation
Improve the effectiveness of each critical
piece of equipment
Set up and implement autonomous
maintenance
Establish a planned maintenance system in
the maintenance department
Provide training to improve operator and
maintenance skills
Develop an early equipment management
program

25. Launching TPM- Stabilization
Perfect TPM implementation
and raise TPM levels

26. Eliminating Equipment Losses

27. Improvement Goals for Chronic Losses

28. OEE

29. What is OEE
 OEE (overall equipment efficiency) is a “best practices” way
to monitor and improve the efficiency of your
manufacturing processes
 machines
 manufacturing cells
 assembly lines

30. OEE Factors
 Plant Operating Time
 Planned production time
 planned downtime ie. breaks
 Availability
 downtime losses
 Performance
 Speed losses
 Quality
 Quality losses

31. World Class OEE
OEE Factor World Class
Availability 90.0%
Performance 95.0%
Quality 99.9 %
OEE 85.0%

32. Calculating OEE
 Availability = Operating time/planned production
 Performance = Ideal Cycle Time / Total Pieces or
(total pieces / Operating time)/Ideal Run time
 Quality = Good Pieces / Total Pieces
 OEE = Availability X Performance X Quality

33. Example OEE Calculation
Item Data
Shift length 8 hrs = 480 min.
Short Breaks 2@ 15 min. = 30 min
Meal Break 1 @ 30 min = 30 min
Down Time 47 min
Ideal Run Time 60 pieces per min
Total Pieces 19,271 pieces
Reject Pieces 423 pieces

34. Availability =
Operating time
Planned production time
 = 373 minutes / 420 minutes
 = 0.8881 (88.81%)

35. Performance =
(Total pieces /Operating time)
Ideal Run Time
 = (19,271 pieces/373 minutes)/60 pieces per minute
 = 0.8611 (86.11%)

36. Quality =
Good Pieces
Total Pieces
 = 18,848 / 19,271 pieces
 = 0.9780 (97.80 %)

37. OEE =
Availability X Performance X Quality
 = 0.8881 X 0.8611 X 0.9780
 = 0.7479 (74.79%)

38. TPM BENIFITS

39. TPM - Benefits
 Improved equipment eliminates the root cause of
defects
 Defects are prevented through planned maintenance
 Preventive maintenance costs are reduced as
equipment operators conduct autonomous
maintenance
 Improved equipment designs ensure that new
equipment naturally produces fewer defects
 Simplified products designs and a redesigned process
produce with few defects
 Engineers, technicians and managers are trained in
maintenance and quality

40. TPM - Benefits
(Japanese TPM Prize winners during 1982-1984)
Equipment failures reduced from 1,000/month
to 20/month
Quality defects reduced from 1.0% to 0.1%
Warranty claims reduced by 25%
Maintenance costs reduced by 30%
WIP decreased by 50%
Productivity improved by 50%. (Patterson &
Fredendall, 1995)