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Total Productive Maintenance
- 1. Lean Tools andMethods: Total Productive Maintenance (TPM) Presented By: Md Muzahid Khan Intekhab Islam Ashik Takvir 1
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- 3. TPM – TheBig Picture Involving employees to maintain their own equipment Emphasizing proactive maintenance Emphasizing preventive maintenance • Improved production • Fewer breakdowns • Fewer stops • Less defects 3
- 4. TPM – TheBig Picture A key tool in Lean Manufacturing Holistic approach to equipment maintenace TPM is a team based maintenace TPM is a never ending journey of continuous improvement 4
- 5. History of TPM Introducedin Japan in 1951 First company to obtain TPM certification 5
- 6. Objectives of TPM Establishinga culture to maximize production effectivenss Organizing shop-floor system to prevent losses Involving all the functions of the organization Achieveing zero losses, breakdowns and defects TPM 6
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- 8. The 5S Foundation 5S Sort Setin order ShineStandardize Sustain 8
- 9. The Eight Pillarsof TPM • Operator feels ownership • Equipment remains well cleaned • Identifies emergent issues Autonomus Maintenance • Reduces unplanned stop times • Maintenance when machine is not in production • Reduces inventory through control of spare parts Planned Maintenance • Removes root source of defects • Reduces number of defects • Reduces cost by catching defects early Quality Maintenance 9
- 10. The Eight Pillarsof TPM • Recurring problems are identfied • Combines the collective talents of a company to ensure continuous improvement Focused Imrpovement • New equipment reaches planned performance faster • Maintenance is simpler and more robust Early Equipment Management • Operators develop skills of maintenance • Managers know about TPM goals and principles Training and Education 10
- 11. The Eight Pillarsof TPM • Safer workplace • Fewer accidents, fewer stops Safety, Health and Environment • Extends TPM benefits beyond the plant floor • Supports production through improved administration TPM in Administration 11
- 12. Roadmap for TPMImplementationStepOne Identify Pilot Area Easiest to improve Constraint/ Bottleneck Most problematic 12
- 13. Roadmap for TPMImplementationStepTwo Restore Equipment to Prime Operating Condition 5S Autonomous Maintenance Inspection Points Visibility Set Points Lubrication Points Operator Training Create Checklist Audit Autonomous Maintenance 13
- 14. Roadmap for TPMImplementationStepThree Start Measuring OEE OEE stands for Overall Equipment Effectivenss • Gold standard for measuring manufactruing productivity • Measuring OEE is a manufacturing best practice OEE Availabilty PerformanceQuality Factors of OEE 14
- 15. Roadmap for TPMImplementationStepFour Address Major Losses 15
- 16. Roadmap for TPMImplementationStepFive Introduce Proactive Maintenance Techniques Create Feedback System Create component log Monthly audit Maintenance interval adjustments Establish Maintenance Intervals Wear based Predicted Failure based Time based Work order based Identify Components Components that wear Components that fail Stress points 16
- 17. Conclusion By implementing TPMa company benefits by • Increased equipment uptime • Increased plant capacity • Lower maintenance and production costs • Lower defects • Enhanced job satisfaction Profit increased by 16 million USD for an investment of 5 million USD Engage employees Aim for early success Provide active leadership Share success stories Rewards Continu ously improve 17
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- 19. References 19 • http://www.leanexpertise.com/TPMONLINE/articles_on_total_productive_maintenance/tpm/tpmroberts.htm • https://www.oee.com/calculating-oee.html •https://www.leanproduction.com/tpm.html • https://www.slideshare.net/oeconsulting/total-productive-maintenance-tpm-maximizing-equipment- effectiveness-for-operational-excellence-by-allan-ung-operational-excellence-consulting?next_slideshow=1 • https://www.slideshare.net/centenvir/presentation-on-total-productive-maintenance • https://hashllp.wordpress.com/2017/02/03/the-eight-pillars-of-tpm/