1. Slide 1
Total Productive Maintenance
TPM
Overview
OLISA Olu. Vincent.
Head, Technical Services/Projects.
In

2. Slide 2
TPM as a Lean Initiative
• Competitive costs require
– Spending control
– Defect control
– Downtime reduction
• TPM = Total Productive Maintenance
– Proactive (with all employees involved)
– Preventive
– Predictive
– Planned

3. Slide 3
Why Change?
• ACTIONS:
– Reduce defect / scrap
– Reduction of lost production time
– Lowest possible cost by reducing waste

4. Slide 4
Lean System
5S
Visual
Factory
T P M
Standardized
Work
Leadership by Example & Commitment
In-Station Process Control
Lean Measures
Employee Involvement & Mutual Respect
Pull system / flow production
Peak Performance
Variation reduction / Six Sigma
Continuous Waste Reduction
Rapid Changeover / Customer-driven lot size

5. Slide 5
7 Wastes
• Transportation
• Excess production
• Added processes
• Motion
• Waiting
• Inventory
• Non-conformance (defectives)

6. Slide 6
Causes of Waste
• Excess Manning
– Poor layout and material presentation
– Rework and extra processes
– Inconsistent / inefficient work methods
• Excess Downtime
– Tooling condition
– Unreliable equipment
– Long changeovers
– Incapable process
• Defectives - Rework or Replace
– Incapable processes or process not
compatible with customer expectations or
design spec (design for mfg)
– Tooling condition
– Operator methods and errors

7. Slide 7
Causes of Waste
• Excess Manning
– Poor layout and material presentation
– Rework and extra processesRework and extra processes
– Inconsistent / inefficient work methods
• Excess Downtime
– Tooling conditionTooling condition
– Unreliable equipmentUnreliable equipment
– Long changeovers
– Incapable processIncapable process
• Defectives - Rework or Replace
– Incapable processes or process not
compatible with customer expectations or
design spec (design for mfg)
– Tooling conditionTooling condition
– Operator methods and errors

8. Slide 8
Effective TPM Eliminates 5 Losses
1. Equipment breakdowns
2. Defects, scrap, and rework
3. Safety Issues
4. Mini stoppages
5. Reduced speed

9. Slide 9
What is TPM??
1. Starts with 5S / Visual Factory
2. Builds a comprehensive Downtime Database by
cause, frequency, and duration
3. Predicts and prevents downtime by PM system
4. Expands role of Operator as first point of early
warning and prevention
5. Develops Professional Maintenance skills
TPM is a Lean tool to optimize the effectiveness of
manufacturing equipment and tooling.

10. Slide 10
1
2
3
4
5
6
7
Operator Autonomous Maintenance
Countermeasures for Contamination
Initial Standards
General Inspection
Autonomous Inspection
Standardization
Aut. Mgt.Seven Steps
of TPM
7
6
5
4
3
2
1
Initial Clean-up

11. Slide 11
TPM is Planned, Predictive, & Preventive
1. Starts with 5S / Visual Factory
2. Builds a comprehensive downtime data
base by cause, frequency, and duration
3. Predicts and prevents downtime by PM
system
4. Expands role of Operator as first point of
early warning and prevention
5. Professional Maintenance

12. Slide 12
5S5S Workplace
SSortort (organize)
SShinehine (clean)
SSet in orderet in order (make orderly and neat)
SStandardizetandardize (visual place for everything)
SSustainustain (maintain the system)
A safe, clean, orderly workplace is
fundamental to quality, efficiency, and teams

13. Slide 13
TPM starts with 5S
• You can’t see problems clearly when
the workplace is in disarray
• Cleaning and organizing the workplace
helps the team to uncover problems
• Making problems visible is the first step
of improvement
• Clean machines and workplace create
pride & Safety

14. Slide 14
Downtime Visual Controls
• Visual or audio alerts
– Abnormality obvious at a glance (e.g. stoppage,
reject, control fault)
– Alerting Maintance team leaders
– Provide real time “scoreboard” for employees
• Machine down light visible from aisle
• Production status board (e.g. actual counts vs. goal)
• Scrap counts and downtime minutes
• Located in clear view in shop (not in control room)
• Simple, self regulating, & employee managed

15. Slide 15
TPM is Planned, Predictive, & Preventive
1. Starts with 5S / Visual Factory
2. Builds a comprehensive
downtime data base by cause,
frequency, and duration
3. Predicts and prevents downtime by PM
system
4. Expands role of Operator as first point of
early warning and prevention
5. Professional Maintenance

16. Slide 16
Downtime Database
• Categorize at a minimum by Equip, Tooling, C/O, Other
• Segmented bar graph for E-T-O lost time
• Subcategories for Equip (e.g.)
– Hydraulic / pneumatic
– Mechanical / lubrication
– Electrical / controls
– Shot-end components
• Subcategories for Tooling (e.g.)
– Slides
– Cores
– Inserts
– Ejector pins
• Subcategories for Other (e.g.)
– Operator error
– Materials

17. Slide 17
Minimum Downtime Tracking
0
20
40
60
80
100
120
Minutes
1Q02 2Q02 Jun Jul Aug Sep Oct Nov Dec
Downtime by Cause 3500 ton Bay
(avg min/shift per Machine)
O
T
E
Equip
Tools
Other

18. Slide 18
TPM is Planned, Predictive, & Preventive
1. Starts with 5S / Visual Factory
2. Builds a comprehensive downtime data
base by cause, frequency, and duration
3. Predicts and prevents downtime
by PM system
4. Expands role of Operator as first point of
early warning and prevention
5. Professional Maintenance

19. Slide 19
Predictive Maintenance Tools
• Rate/hr vs. target or historical normal output (B/W)
• Database
– MP2 / maintenance history
– statistical probability (frequency & duration)
• Physical prediction of impending failure
– Sound (bearing)
– Temperature (cooling water)
– Flash (core pins)
– Shot monitoring system
– SPC on part geometry
– Hydraulic pressure (ejector pins)
– Spindle loads (amps)
– Fluids / Lubrication analysis (milipore)
– Vibration Signature Analysis

20. Slide 20
Preventive Maintenance System
• History of downtime by major machine & tool
– Downtime measurement & tracking
– Mean Time Between Failures
– Average downtime
– Pareto of causes at component level (eg L/S or temp sensor)
– Cost to maintain
• Develop PM cards based on frequency of failure and magnitude of
average lost time (start small & grow)
– Limit & prox switches
– Shot tip / sleeve
– Critical frame and cylinder mounting bolts
– Expendable tools
– Valves, hoses, packing, seals
• PM’s have instruction, schedule/frequency & sign-off
– PM’s / repairs done in window of opportunity when machine is down
– Cycle count or date based execution of PM’s (eg cutter change)
– PM status visual (work completed / not completed)

21. Slide 21
TPM is Planned, Predictive, & Preventive
1. Starts with 5S / Visual Factory
2. Builds a comprehensive downtime data base by
cause, frequency, and duration
3. Predicts and prevents downtime by PM system
4. Expands role of Operator as first point
of early warning and prevention
• One point lessons for operator awareness
• Creates OMP (Operator - Maintenance
Partnership)
• Operator performs checks, problem
solving, and improvements
1. Professional Maintenance

22. Slide 22
TPM
Production Operators
• Clean & Check
• Observe
• Categorize
Manufacturing Engineers
• Equipment Planning
• Equipment Studies
Production Planning
& Control
• Schedule P.M.
Quality Engineers
• Standards &
Calibrations
Active
Planned
Maintenance
Process

23. Slide 23
OMP - Operator Maintenance Partnership
• Operator training in TPM
• Operator basic equip inspection
& tooling checks
• Operator basic cleaning
• Operator lubrication check
• One point lessons (capture
knowledge)
• TPM Board & TPM Tags
(proactive operator involvement)
TPM

24. Slide 24
TPM Tag System
• Problem communication tool to and from
maintenance, tool room, and production
– Identify abnormal machine conditions
• Record problem discovered by operator
• Record problem found during scheduled PM
– Status tracking system of requested repairs
– TPM visual management tool (hang tags)
– Repair history for future problem solving
• TPM Tag used for recording problem & fix
– Blue Tag-Operator or Maint responsible to repair
– Red Tag- Safety-related request (priority)

25. Slide 25
Operator/Supervisor Production Management Maintenance
1. Abnormality Identified
2. Fill out Tag Red= Safety
Blue= Prod/Maint
3. Hang C-tag as close to the defect
as possible
4. Hang A &B Tags on the TPM Tag
status board by Machine location and
area of responsibility to correct.
5.Maintenance evaluates problem. If
fixed immediately go to 6. If parts or
time needed, maint pulls A tag from
board. The A tag is MWO. The B
tag is posted on the Maint WO
status section of the TPM Board
with est. timing.
7. Operator/Supervisor check to see
if work was done.
6.After work is completed,
maintenance completes back side of
A tag and places both the A & B
tag in the work completed box
8. If OK, Operator/ supervisor
removes C tag from machine and
places ABC tags in Completed box. If
not OK, tags stay and maint is
contacted. Contact noted on tag.
9. Production management reviews
the information. Also reviews the
comments and takes actions if
required. Places tag in history file box
located in the office
Tag information is recorded and reviewed for continuous improvement of PM
database by Production and Maintenance; Repeat operator tags may indicate
Maint needs to investigate.
Tag Process

26. Slide 26
TPM is Proactive, Predictive,
Preventive & Planned
1. Starts with 5S / Visual Factory
2. Builds a comprehensive downtime data
base by cause, frequency, and duration
3. Predicts and prevents downtime by PM
system
4. Expands role of Operator as first point
of early warning and prevention
5. Professional Maintenance

27. Slide 27
Professional Maintenance
• Equip Safety
• Skill building
• Cross-training
• Area Maintenance
• WC MRO stores
• Maint Mgmt System
• Down alarms
• Radios
• Planned PM

28. Slide 28
1
2
3
4
5
6
7
Operator Autonomous Maintenance
Countermeasures for Contamination
Prepare Temporary Standards
General Inspection
Autonomous Inspection
Standardization
Aut. Mgt.
7 Steps
7
6
5
4
3
2
1
Initial Clean-up
OIL
T P M

29. Slide 29
TPM
5S
TPM I
Step 1
Step 2
Step 3
TPM II
Step 4
Step 5
Step 6
Step 7
Initial Focus
prerequisite for TPM I

30. Slide 30
STEP 3: Prepare Temporary Standards
This step is to enhance the equipment reliability
& maintainability.
• Temporary Check Sheet For Clean-Up,
Lubrication, Start-up, and Shut-down:
– What items need to be done
– Who will perform the check
– How often to check
– Where the location is to be checked
– What to use for the inspection or cleaning
– Target time to complete the task

31. Slide 31
TPM Summary
• TPM = Total Productive
Maintenance
– Proactive (all employees
involved)
– Preventive
– Predictive
– Planned
• TPM is an integral part
of JLF Total Quality
production System
5S
Visual
Factory
T P MT P M
Standardized
Work
Continuous Waste Reduction
Peak Performance

32. Slide 32
TPM is a Lean tool for
Quality and
Productivity