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Total Productive Maintenance

LEAN SIX SIGMA

Sanmina-SCI
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 Total Productive Maintenance

What is Total Productive Maintenance?

A powerful Lean tool to optimize use and availability of

manufacturing tooling by giving daily operators the empowerment
to properly maintain them.

Operators are the first option an operation has to prevent

unscheduled maintenance needs due to unexpected equipment
breakdowns.

As part of their daily operation, workers become familiar with

proper equipment functioning and their familiarity with the
equipment can be used to prevent failures.
LEAN SIX SIGMA
Sanmina-SCI

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 Total Productive Maintenance

How does TPM work?

Equipment proper functioning requires periodic and consistent

maintenance practices (cleaning, lubrication, inspection,
adjustment, parts replacement, etc.)

This practices frequency depends on equipment technology, use

and fabrication specifications.

By creating basic maintenance simple instructions and properly

establishing their periodicity, they can be integrated into daily
workers standard work instructions.

LEAN SIX SIGMA

Sanmina-SCI

Sanmina-SCI Confidential
 Total Productive Maintenance

How does TPM work?

Reactive
Maintenance done hen machine is broken (if it isn’t broken, don’t
fix it)

Preventative
Routine maintenance is done on a scheduled based on
convenience, usage and inspection

Predictive
Equipment is monitored for signs of change and maintenance is
done as soon as conveniently possible

LEAN SIX SIGMA

Sanmina-SCI

Sanmina-SCI Confidential
 Total Productive Maintenance

Causes for Machine Failures

• Abrasion
• Abuse
• Vibration
• Wear
• Corrosion
• Contamination
• Age deterioration
• Bond separation
• Shock
• Fatigue
• Negligence
• Lack of consumables
• Dirt

LEAN SIX SIGMA

Sanmina-SCI

Sanmina-SCI Confidential
 Total Productive Maintenance

Maintenance Common Metrics

• Common metrics to consider are:

•Mean time between maintenance (MTBM)
•Mean time between failures (MTBF)

• MTBM and MTBF can be applied to both preventive and

reactive maintenance

• It is also convenient to record the amount of time required to

provide equipment maintenance.

LEAN SIX SIGMA

Sanmina-SCI

Sanmina-SCI Confidential
 Total Productive Maintenance

Reactive Maintenance

• Fix machine until it is broken

• Disadvantages:
• No scheduling around repair times
• May occur at worst times
• Can be the lead to catastrophic damages
• Causes major disruptions to operation
• May have to wait for highly specialized parts or highly
specialized technicians.

LEAN SIX SIGMA

Sanmina-SCI

Sanmina-SCI Confidential
 Total Productive Maintenance

Preventative Maintenance

• Provides basic upkeep activities (e.g.: lubrication and part

replacement) on machines at scheduled intervals
• Requires failure types that provide some level of warning

• Advantages
• Larger maintenance activities scheduled during outages
• Replacement of parts can be scheduled

• Disadvantages
• Requires regular inspections
• Some problems might be missed

LEAN SIX SIGMA

Sanmina-SCI

Sanmina-SCI Confidential
 Total Productive Maintenance

Predictive Maintenance

• Using a sampling method on machine characteristics that

when analyzed provide information that equipment is nearing
failure

• Requires failure types that provide progressive warning

Advantages
Parts are replaced on as needed basis
Can be planned for downtime
Economically based decisions can be made
Good for banks of similar equipment
Best for failures that follow distribution.

Disadvantages
Require significant machine knowledge and data collection
LEAN SIX SIGMA
Sanmina-SCI

Sanmina-SCI Confidential