Total Productive maintenance (TPM)

TOTAL = All encompassing by maintenance and production individuals working together PRODUCTIVE = Production goods and services that meet or exceed customers’ expectations MAINTENANCE = Keeping equipment and plant in as good as or better than the original conditions at all times Productive maintenance (PM) originated in the U.S. in late 1940’s early 1950’s Japanese companies modified and enhanced it to fit the Japanese industrial environment The first use the term TPM was in 1961 by Nippondenso, a Japanese auto components manufacturer Seiichi Nakajima – head of JIPM, one of the earliest proponents, known as the Father of TPM

• Laura Dietrich: Maintenance Manger

• Antoinette Lockett: Plant Manger

• Waseem Manzoor: Quality Manger

• Xiaoyan Liu: Production Manger

Meeting Agenda

I Understanding Downtime -Group

II Major Losses of TPM -Antoinette Lockett

I Planned Downtime Losses -Xiaoyan Liu

II Unplanned Downtime Losses -Laura Dietrich III Reduce Speed Losses-

IV Poor Quality Losses -Waseem Manzoor

III Total Productive Maintenance

I What is TPM -Antoinette Lockett

II Breakdown of TPM -Laura Dietrich

III TPM History -Laura Dietrich

IV TPM Evolution

V Goal of TPM -Antoinette Lockett

VI Three Principles of Prevention

Meeting Agenda Cont.

I TPM-8 Pillars-Laura Dietrich

II Kick off TPM

I Launching TPM- Preparatory Stage-Antoinette Lockett

II Autonomous Maintenance- Xiaoyan Liu

III Equipment Management Life Cycle- Xiaoyan Liu

IV TPM Implementation-Waseem Manzoor

V Launching TPM- Stabilization-Waseen Manzoor

VI Eliminating Equipment Losses-Laura Dietrich

VII Improvement Goals for Chronic Losses-Laura Dietrich III Overall Equipment Efficiency

I What is OEE-Xiaoyan Liu

II OEE Factors-Xiayon Liu

III Calculating OEE-Waseem Manzoor

IV TPM Benefits-Xiaoyan Liu

Understanding Downtime

MAJOR LOSSES

Planned Downtime losses

• Start-ups

• shift changes

• coffee and lunch breaks

• planned maintenance shutdowns

Unplanned Downtime Losses

• Equipment breakdown

• Changeovers

• Lack of material

Reduced Speed Losses

• Idling and minor stoppages

• Slow-downs

Poor Quality Losses

• Process non-conformities

• Scrap

TPM

What is Total Productive

• TOTAL = All encompassing by

maintenance and production

individuals working together

services that meet or exceed

customers’ expectations

and plant in as good as or better than the original conditions at all times

Breakdown of TPM

TPM - History

• Productive maintenance (PM) originated in the U.S in late 1940’s & early 1950’s

• Japanese companies modified and enhanced

it to fit the Japanese industrial

environment

• The first use the term TPM was in 1961 by Nippondenso, a Japanese auto components manufacturer

• Seiichi Nakajima – head of JIPM, one of

the earliest proponents, known as the

Father of TPM

Goals of TPM

1 Aims at getting the most effective use of

equipment

2 Builds a comprehensive PM system

3 Brings together people from all departments

concerned with equipment

4 Requires the support and cooperation of

everyone from top managers down

5 Promotes and implements PM activities based

on autonomous small group activities.

6 Maintaining Equipment for life

7 Encouraging input from all employees

Three Principles of Prevention

• Maintenance of normal conditions

• Early discovery of abnormalities

• Prompt response

TPM 8 PILLARS

Kick off TPM

Launching TPM- Preparatory Stage

• Announce top management’s decision

• Establish basic policies

• Form a master plan for implementing

Launching TPM- Preliminary

Implementation

• Improve the effectiveness of each critical piece of equipment

• Set up and implement autonomous

• Perfect TPM

implementation and raise

TPM levels

Launching TPM- Stabilization

Eliminating Equipment Losses

Improvement Goals for Chronic Losses

OEE

What is OEE

• OEE (overall equipment efficiency) is

a “best practices” way to monitor and improve the efficiency of your

manufacturing processes

– machines

– manufacturing cells

– assembly lines

OEE Factors

• Plant Operating Time

• Planned production time

– planned downtime ie breaks

World Class OEE

OEE Factor World Class

(total pieces / Operating time)/Ideal Run time

• Quality = Good Pieces / Total Pieces

• OEE = Availability X Performance X

Quality

Example OEE Calculation

Shift length 8 hrs = 480 min.

Short Breaks 2@ 15 min = 30 min

Meal Break 1 @ 30 min = 30 min

Ideal Run Time 60 pieces per min

Total Pieces 19,271 pieces

Performance =

(Total pieces /Operating time) Ideal Run Time

• = (19,271 pieces/373 minutes)/60 pieces per minute

• = 0.8611 (86.11%)

Quality =

Good Pieces Total Pieces

• = 18,848 / 19,271 pieces

• = 0.9780 (97.80 %)

OEE =

Availability X Performance X Quality

• = 0.8881 X 0.8611 X 0.9780

• = 0.7479 (74.79%)

TPM BENIFITS

• Preventive maintenance costs are reduced as

equipment operators conduct autonomous

maintenance

• Improved equipment designs ensure that new

equipment naturally produces fewer defects

• Simplified products designs and a redesigned

process produce with few defects

• Quality defects reduced from 1.0% to 0.1%

• Warranty claims reduced by 25%

• Maintenance costs reduced by 30%

• WIP decreased by 50%

• Productivity improved by 50% (Patterson & Fredendall, 1995)

TPM – Success stories

• USPS Albany, New York: annual save of

$86,000; could save $4.5 million if applied nationwide

• Yamato Kogyo Corp., Japan: