En Introduction to TPM - Objectives and Benefits

Introduction to TPM – Objectives and Benefits

September 29, 2008

The Five Pillars of TPM The Five Pillars of TPM TPM TPM TPM

Cross-Functional, Team-Based Improvement Activities

Textbook Definition

“TPM is a plant improvement methodology which enables continuous and rapid improvement

through use of employee involvement, employee empowerment, and closed-loop measurement of

results.”

TPM Implementation – Nakajima’s 12 Steps1. Announce Top Management’s Decision to Introduce TPM2. Launch Educational Campaign3. Create Organizations to Promote TPM4. Establish Basic TPM Policies and Goals5. Formulate a Master Plan for TPM Development6. Hold TPM “Kickoff”7. Improve Equipment Effectiveness8. Establish an Autonomous Maintenance Program for Operators9. Set-up a Scheduled Maintenance Program for the Maintenance

Department10. Conduct Training to Improve Operation and Maintenance Skills11. Develop Initial Equipment Management Program12. Implement TPM Fully and Aim for Higher Goals

Characteristics of TPM

Optimum relationships between people and equipment/processInvolvement of everyone, from top leadership to shopfloor workersA cross-functional approach, involving all departmentsImplementation through small group teamworkDATA DRIVEN!!!

Two Types of Teams

Manager

Natural teamNatural team

Manager

Natural teamNatural team

CrossCross--functionalfunctional

Definition(s)

Note: The DREADED “M” word is not used!!!

So what does maintenance mean anyway…

Maintenance = The act of maintainingMaintain = To keep in a state of order. To keep in

due (rightful, proper, fitting) condition, operation, or force; keep unimpaired.

Definition(s) cont…Fix and Repair = Maintenance

HOZEN (Maintenance in Japanese) = Maintaining and preserving perfection through Asset Management.

TPM = Total Productive ManagementTPM = Total Productive Manufacturing

TPM Goals

Zero accidents

Minimum life cycle cost

Zero unplanned downtime

Zero speed losses

Zero defects

Zero waste!

Results

Overall Equipment Effectiveness (OEE) Improved

Mean Time Between Failure Improved

Mean Time To Repair Improved

Etc…

Actual “GREEN” Results$60K/ Month Facilities Maintenance Savings

$700K Annual Savings “Other-than-hazardous-waste”

• TPM Process applied to facilities maintenance activities

Plant Air System

Plant Lighting during peak Kilowatt usage

Plant Start-up/Shut-down Procedures

Waste Water Treatment System

Note: Above results since 1998

TPM Is a Paradigm Shift

Old Attitude“I operate, you fix”

“I fix, you design”

“I design, you operate”

Old Attitude“I operate, you fix”

“I fix, you design”

“I design, you operate”

TPM Attitude“We are all responsiblefor our equipment,our plant, andour future”

Training and Skill Development

Why Training and Skill Development

Operators and Maintenance: • Should possess the training and skills

necessary to carry out all of the required TPM activities so that they have…

A clear understanding of the criteria for judging normal and abnormal conditionsCan be empowered to strictly enforce condition management rulesThe ability to quickly respond to any and all abnormalities

Early Equipment Management (EEM) and Maintenance Prevention

(MP) Design

EEM and MP Design

EEM and MP Design are two methods of making improvements at the earliest possible stage, with the goal of “fix and repair” and defect free equipment.

In other words…Operator/Maintenance friendly equipment through lessons learned on existing equipment and applied to new equipment during the concept, design, and installation phase(s).

EEM/MP Design Involvement

EEM/MP Design is a team approach. The team should ALWAYS include members from…

Maintenance (hourly)Production (hourly)Engineering/Technical

Maintenance Process Improvement (MPI)

(Planned, Scheduled Maintenance System)

MPI Tools and Activities

Well trained/skilled craftspeopleLubrication ManagementPreventive Maintenance systemPredictive TechnologiesDocumentation ManagementEEM/MP Design InvolvementMaintenance Management SystemSpare Parts Management

The Maintenance Techniques

Preventive Maintenance – preventing breakdownsCorrective Maintenance – improving or modifying equipment to prevent breakdowns or to make maintenance easierMaintenance Prevention – designing and installing equipment that needs little or no maintenanceBreakdown Maintenance – repairing or fixing after breakdowns occur

Systematic Equipment Improvement

(Improve Equipment Effectiveness)

A systematic approach to eliminate waste through analysis of the “6” major losses utilizing cross-functional teams to continuously investigate, test, and implement improvements with a goal of maximizing equipment effectiveness.

DATA DRIVEN PROCESS!!!

Six Major Losses toEquipment Effectiveness

Failures

Setup/changeover and adjustments

Idling and minor stoppages

Reduced speed

Defects and rework

Startup loss

How the Losses Reduce Effectiveness

QualityPerf.EfficiencyAvailability

OverallEquipment

Effectiveness= xx

ReducedSpeed

StartupLosses

Minor Stopsand Idling

Adjustmentsand Set-Ups

EquipmentFailures

Rejects andDefects

6 MajorLosses

Autonomous Maintenance

What IsAutonomous Maintenance?

A collaborative team activity involving production, maintenance, and engineeringAn approach that• develops operating and maintenance skills• strengthens communication and cooperation

A series of activities implemented in well-defined developmental steps

Seven Steps ofAutonomous Maintenance

1. Conduct initial cleaning/inspection

2. Eliminate sources of contamination

3. Establish provisional standards

4. Develop general inspection training

5. Conduct general inspections

6. Improve workplace management and control

7. Participate in advanced improvement activities

Cross-Functional Team Activity

Zero Breakdown Strategies

Restore equipmentMaintain basic equipment conditionsAdhere to standard operating proceduresImprove operator maintenance skillsDon’t stop at emergency fixesCorrect design weaknessesStudy breakdowns relentlessly

“Button-pushers” to Process Owners

“Firefighters” to Maintainers

En Introduction to TPM - Objectives and Benefits

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