Successfully reported this slideshow.
We use your LinkedIn profile and activity data to personalize ads and to show you more relevant ads. You can change your ad preferences anytime.

Total Productive Maintenance (TPM) Frameworks

This presentation is a collection of PowerPoint diagrams and
templates used to convey 24 different TPM Excellence
frameworks/models. They include:

1. TPM Excellence Framework
2. 12 Steps of TPM Implementation
3. TPM Implementation Structure
4. TPM Paradigm
5. Machine Loss Pyramid
6. Bathtub Curve
7. 6 Major Equipment Losses
8. Overall Equipment Effectiveness (OEE)
9. Goals of Autonomous Maintenance
10. Autonomous Maintenance Approach
11. 3 Key Tools for AM Activities
12. 7 Steps of Autonomous Maintenance
13. Planned Maintenance Approach
14. 6 Steps of Planned Maintenance
15. Preventive Maintenance Approach
16. 5S Principles
17. 6 Steps of Kaizen
18. Cause & Effect Diagram
19. 5 Whys Technique
20. Visual Management Pyramid
21. Mistake Proofing Process
22. 8 Types of Waste
23. Deming Cycle
24. PDCA Problem Solving Process

To download this complete presentation, visit:
https://www.oeconsulting.com.sg/training-presentations

Related Books

Free with a 30 day trial from Scribd

See all
  • Be the first to comment

Total Productive Maintenance (TPM) Frameworks

  1. 1. © Operational Excellence Consulting. All rights reserved. This presentation is a collection of PowerPoint diagrams and templates used to convey 24 different TPM Excellence frameworks/models. Total Productive Maintenance (TPM) Frameworks Diagrams & Templates of Total Productive Maintenance (TPM) Frameworks & Models
  2. 2. © Operational Excellence Consulting. All rights reserved. 2 Contents 1. TPM Excellence Framework 2. 12 Steps of TPM Implementation 3. TPM Implementation Structure 4. TPM Paradigm 5. Machine Loss Pyramid 6. Bathtub Curve 7. 6 Major Equipment Losses 8. Overall Equipment Effectiveness (OEE) 9. Goals of Autonomous Maintenance 10. Autonomous Maintenance Approach 11. 3 Key Tools for AM Activities 12. 7 Steps of Autonomous Maintenance 13. Planned Maintenance Approach 14. 6 Steps of Planned Maintenance 15. Preventive Maintenance Approach 16. 5S Principles 17. 6 Steps of Kaizen 18. Cause & Effect Diagram 19. 5 Whys Technique 20. Visual Management Pyramid 21. Mistake Proofing Process 22. 8 Types of Waste 23. Deming Cycle 24. PDCA Problem Solving Process NOTE: This is a PARTIAL PREVIEW. To download the complete presentation, please visit: http://www.oeconsulting.com.sg
  3. 3. © Operational Excellence Consulting. All rights reserved. 3 The Total Productive Maintenance (TPM) excellence framework provides a holistic approach to improve capital productivity TPMintheOffice Safety,Health&Environment AutonomousMaintenance PlannedMaintenance FocusedImprovement EarlyEquipment Management QualityMaintenance Education&Training 5S & Visual Management TPM Goals: Zero Defects, Zero Breakdowns, Zero Accidents Source: Japan Institute of Plant Maintenance (JIPM) TPM Excellence Framework
  4. 4. © Operational Excellence Consulting. All rights reserved. 4 The 12 Steps of TPM Implementation define a systematic approach for the planning and deployment of TPM activities TPM Implementation Model Preparation Kick-off Implementation 1. Announcement to introduce TPM 2. Introductory education campaign for the workforce 3. TPM Promotion (special committees) 4. Establish basic TPM policies and goals 5. Preparation and Formulation of a master plan 7. Develop an equipment management program 8. Develop a planned maintenance program 9. Develop an autonomous maintenance program 10. Increase skills of production and maintenance personnel 12. Perfect TPM implementation and raise TPM levelsStabilization 11. Develop early equipment management program 6. Invite customers, affiliated companies and subcontractors Source: Seiichi Nakajima
  5. 5. © Operational Excellence Consulting. All rights reserved. 5 The TPM Implementation Structure provides guidance on how to set up an organization for TPM governance TPM Implementation Structure TPM Responsible (Plant Manager) Focused Improvement Autonomous Maintenance Education & Training Planned Maintenance Safety, Health & Environment Early Equipment Management Office TPM Quality Maintenance TPM Promotion Office
  6. 6. © Operational Excellence Consulting. All rights reserved. 6 TPM is a paradigm shift towards teamwork and collaboration between Production and Maintenance departments Old Attitude TPM Attitude I use I maintain & I fix We maintain Maintenance Operator MaintenanceOperator TPM Paradigm
  7. 7. © Operational Excellence Consulting. All rights reserved. 7 The Machine Loss Pyramid underscores the philosophy of TPM – the need to listen and watch for anomalies and taking action before the breakdown Source: Adapted from Heinrich’s Law on Safety The Machine Loss Pyramid 1 10 30 Hundreds Breakdown (function loss) Minor Stoppage (function reduction) Minor Failures (no function reduction) Hidden Failures (no function reduction) Motor burns out Motor overheating Vibration causes bearing deterioration Lose nuts and bolts Example
  8. 8. © Operational Excellence Consulting. All rights reserved. 8 The useful life of equipment can be extended by a preventive maintenance program as part of a holistic TPM framework Time Infant Mortality Failures Useful Life Failures (Constant Failure Rate) Wear-Out Failures FailureRate 0 TPM extends useful life of equipment Overview of TPM The Bathtub Curve
  9. 9. © Operational Excellence Consulting. All rights reserved. 9 Overall Equipment Effectiveness (OEE) can be improved by eliminating the six major equipment losses Overall Equipment Effectiveness Availability Breakdowns Setups & Adjustments Performance Reduced Speed Minor Stops & Idling Quality Defects & Rework Startup & Yield Loss Six Big Losses Source: Japan Institute of Plant Maintenance (JIPM) Six Major Equipment Losses
  10. 10. © Operational Excellence Consulting. All rights reserved. 10 The Overall Equipment Effectiveness (OEE) is a measure of how well a manufacturing operation is utilized compared to its full potential Source: Japan Institute of Plant Maintenance (JIPM) Overall Equipment Effectiveness (OEE) Six Big Losses Downtim e Losses Quality Losses Speed Losses Fully Productive Time Net Operating Time Planned Production Time Operating Time Equipment Average total operating loss 30-50% Breakdowns Setups & Adjustments Reduced Speed Minor Stops & Idling Defects & Rework Startup & Yield Loss Breakdowns per machine (stopped longer than 10 mins) – less than once a month Setup/adjustment time – less than 10 mins Achieve ideal cycle times (design speed); increase 15% or more Minor stoppages and idling per machine – under 10 mins Rate (including products to be reworked) – less than 0.1% Startup yield – 99% or more of lot Ideal Cycle Time x Total Pcs Operating Time Good Pieces Total Pieces Operating Time Planned Production Time Availability Quality Performance Greater than 90% Throughput process - Greater than 99% Greater than 95% OEE Factors OEE = Availability x Performance x Quality
  11. 11. © Operational Excellence Consulting. All rights reserved. 11 The Check-Act-Plan-Do cycle is the basic approach for Autonomous Maintenance activities Source: Adapted from Society for Maintenance & Reliability Professionals Check ActPlan Do Examine and expose problems Counter and solve problems Execute and follow standards and rules Prevent recurrence through improvement Autonomous Maintenance Approach
  12. 12. © Operational Excellence Consulting. All rights reserved. 12 The seven steps of AM activities outline a systematic approach for operators to implement AM on the shopfloor Seven Steps of Autonomous Maintenance 1. Clean and inspect 2. Eliminate problem sources and inaccessible areas 3. Draw up cleaning and lubricating standards 4. Conduct general inspections 5. Conduct autonomous inspections 6. Standardize through visual workplace management 7. Implement autonomous equipment management
  13. 13. © Operational Excellence Consulting. All rights reserved. 13 § Preventive Maintenance § Corrective Maintenance § Maintenance Prevention § Breakdown Maintenance § Support for Autonomous Maintenance § Specialized maintenance skills § Equipment repair skills § Inspection and measurement skills § Equipment diagnostic skills § Develop new maintenance technologies Planned Maintenance: Main Activities Improvement of Equipment à MTBF Improvement of Maintenance Skills à MTTR The dual focus of Planned Maintenance is improvement of equipment (machine focus) and improvement of maintenance skills (people focus) Planned Maintenance Approach
  14. 14. © Operational Excellence Consulting. All rights reserved. 14 Preventive maintenance which includes cleaning, checking, lubrication and adjustment is health management for machines Daily prevention Early treatment Prevent Deterioration – through daily maintenance (cleaning, checking, lubrication, adjustment) Restore Deterioration – through preventive repairs before problems occur Health checkups Measure Deterioration – through routine inspections and operating checks Preventive medicine Preventive maintenance Preventive Maintenance Approach
  15. 15. © Operational Excellence Consulting. All rights reserved. 15 The 6 Steps of Kaizen is a scientific method which can be used to improve the OEE of an equipment through Kaizen events Source: Kato & Smalley 1. Discover Improvement Potential 3. Generate Original Ideas 2. Analyze the Current Methods 4. Develop an Implementation Plan 5. Implement the Plan 6. Evaluate the New Method Kaizen Six Steps of Kaizen
  16. 16. © Operational Excellence Consulting. All rights reserved. 16 The 5 Whys technique is applied by repeatedly asking the question “Why?” which can drill down the symptoms and lead to the root cause of a problem 5 Whys Technique Why? Because… 1 Why won’t your car start? It ran out of gas. 2 Why did it run out of gas? I forgot to fill it up. 3 Why did you forget to fill it up? The fuel gage doesn’t work. 4 Why doesn’t the fuel gage work? I forgot to have it repaired. 5 Why did you forget to repair it? I did not write it on the repair list when it broke. Root Cause
  17. 17. © Operational Excellence Consulting. All rights reserved. 17 The Visual Management Pyramid defines the types of “tools” that can be applied to achieve the desired objectives Visual Management Pyramid Source: Practical TPM by James Leflar Prevent Abnormalities Detect Abnormalities Warn about abnormalities Build standards into the workplace Share established standards Share information and/or results of control activities Sort, Set in order, Shine, Standardize & Sustain Visual Display 5S Visual Control Poke-Yoke
  18. 18. © Operational Excellence Consulting. All rights reserved. About Operational Excellence Consulting
  19. 19. © Operational Excellence Consulting. All rights reserved. 19 About Operational Excellence Consulting • Operational Excellence Consulting is a management training and consulting firm that assists organizations in improving business performance and effectiveness. • The firm’s mission is to create business value for organizations through innovative operational excellence management training and consulting solutions. • OEC takes a unique “beyond the tools” approach to enable clients develop internal capabilities and cultural transformation to achieve sustainable world-class excellence and competitive advantage. For more information, please visit www.oeconsulting.com.sg
  20. 20. © Operational Excellence Consulting. All rights reserved. END OF PREVIEW For more presentations and templates, please visit: www.oeconsulting.com.sg

    Be the first to comment

    Login to see the comments

  • CandraWibowo

    Apr. 9, 2020
  • ramachandrarao9699

    May. 9, 2020
  • AbdelilahSlimani

    Jun. 4, 2020
  • SurenderJhagtaMainte

    Jun. 23, 2020
  • senion

    Mar. 14, 2021

This presentation is a collection of PowerPoint diagrams and templates used to convey 24 different TPM Excellence frameworks/models. They include: 1. TPM Excellence Framework 2. 12 Steps of TPM Implementation 3. TPM Implementation Structure 4. TPM Paradigm 5. Machine Loss Pyramid 6. Bathtub Curve 7. 6 Major Equipment Losses 8. Overall Equipment Effectiveness (OEE) 9. Goals of Autonomous Maintenance 10. Autonomous Maintenance Approach 11. 3 Key Tools for AM Activities 12. 7 Steps of Autonomous Maintenance 13. Planned Maintenance Approach 14. 6 Steps of Planned Maintenance 15. Preventive Maintenance Approach 16. 5S Principles 17. 6 Steps of Kaizen 18. Cause & Effect Diagram 19. 5 Whys Technique 20. Visual Management Pyramid 21. Mistake Proofing Process 22. 8 Types of Waste 23. Deming Cycle 24. PDCA Problem Solving Process To download this complete presentation, visit: https://www.oeconsulting.com.sg/training-presentations

Views

Total views

655

On Slideshare

0

From embeds

0

Number of embeds

2

Actions

Downloads

0

Shares

0

Comments

0

Likes

5

×