Total Productive Maintenance

ISYE650 Class PresentationSpring 2014

By Akhil Yelisetti

TPM overview

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T P MTotal Productive

Maintenance

What’s TPMHow TPM

works

Concept Zero

TPM TargetsWhy TPM

Objectives of TPM

What’s T P M

• TPM was developed in the 1970's as a method of involving machine operators in the preventive maintenance of their machines – a reaction to increasing specialization and

centralization of the maintenance function that had created division-of-labor barriers between operators and the maintenance of their machines and equipment.

– Also creating a sense of ownership in workers with Autonomous Maintenance

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Objectives of T P M• The overriding objective of TPM is the

elimination of LOSSES. Losses, or waste, includes equipment downtime, defects, scrap, accidents, wasted energy, and labor inefficiency.

• TPM was introduced to achieve some of the following important objectives:– Safer working environment, Job security– Producing goods with improved quality and

machine reliability– Improved financial performance– Produce a low batch quantity at the earliest

possible time.– Goods send to the customers must be non

defective

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Why T P M

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Before 1 Severe problem occured, there were 300 minor and 29 major problems to handle.

Source: Kaizen Institute, Frankfurt

Heinrich‘s Law

TPM is a tool which addresses potential signs of machine break-downs and is therefore an important instrument to prevent total machine crashes.

1

29

300

Severe problem

Minor problems

Major problems

Concept ZERO

• The goal of TPM is to drive all waste to zero: Zero Accidents, Zero Defects, Zero Breakdowns.

• The Concept of Zero is built upon Poka-Yoke, in the design of the process to make it impossible to make and pass on defects.

• Poka-Yoke concepts are also commonly applied to equipment to prevent breakdowns.

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Performance Measure and 6 Losses

• OEE is the performance measure of TPM.• Thus factors affecting OEE / TPM:

• Availability• Performance• Quality

– Associated 6 big losses are:• Availability Losses: Breakdown losses caused

by the equipment; Set-up and adjustment losses

• Performance Losses: Minor stoppage losses; Speed losses

• Quality Losses: Quality defect and rework losses; Yield losses

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Pillars of TPM

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How it Works

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Types of Maintenance • Breakdown Maintenance: This occurs when

equipment fails but does not affect production or operation or extra costs other than repairs

• Preventive Maintenance: A daily maintenance designed to maintain equipment against failing and also improved health condition– Periodic Maintenance: A time based maintenance– Predictive Maintenance: Maintenance based on

condition monitoring by employing surveillance system

• Corrective Maintenance: Redesigning equipment with weakness to improve reliability

• Maintenance Prevention: This indicates design of new machine by Cross functional teams after thorough study on weakness of current machines

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TPM Targets

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P roduction:Obtain Minimum 80% OPE.Obtain Minimum 90% OEE ( Overall Equipment Effectiveness )Run the machines even during lunch. ( Lunch is for operators and not for machines!)

Q uality:Operate in a manner, so that there are no customer complaints.

C osts:Reduce the manufacturing cost by 30%.D elivery:Achieve 100% success in delivering the goods as required by the customer.

S afety:Maintain a accident free environment.

M aintenance:Develop Multi-skilled and flexible workers. And Cross functional teams

References

• http://www.plant-maintenance.com/articles/tpm_intro.shtml

• http://www.leanproduction.com/tpm.html• http://technologyinterface.nmsu.edu/fall97/m

anufacturing/tpm2.html• https://www.moresteam.com/lean/tpm.cfm• http://www.epa.gov/lean/environment/method

s/tpm.htm• http://www.slideshare.net/exerciselean/tpm-pr

esentation-1522308?qid=647eedce-04f7-4ddf-9625-6acfb0bc419d&v=default&b=&from_search=10

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Queries

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