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Data for example

Item Data
Number of Shifts 2 (morning, mid-day
Shift Length 8 hours (480 minutes)
Breaks (2 x 15 minutes) + (1 x 30 minute)
Changeover Time 20 + 14 minutes
Other Stoppage Time 30 + 10 + 20 minutes
Ideal Cycle Time 1.0 seconds
Total Produced 38,542 widgets
Number of Rejects 846 widgets

Calculations 2
Run Time - the amount of time that production was
actually running. Stop Time should include
both Unplanned Stops (e.g. Breakdowns) or Planned
Stops (e.g., Changeovers).
Formula: Planned Production Time ­  Stop Time
Example:
840 ­ (20+14+30+10+20) = 746 minutes

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Other benefits of using OEE

Reduced
 Inventory - by enabling smaller batches
 Waiting - by cutting changeover time and
production lead time
 Over-production - to compensate for defects
 Defects - through shorter changeover, fewer
breakdowns, proper maintenance

Total
Productive
Maintenance

This Photo by Unknown Author is licensed under CC BY-NC

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Key Concepts of TPM

 Involve operators in maintaining their own

equipment.
 Emphasize proactive and preventive maintenance.
 Strive to achieve perfect production:
 No Breakdowns
 No Small Stops or Slow Running
 No Defects
 Create a safe working environment.

6 Big Losses
SMED TPM

Stopping

Set-up 
Breakdown 
Slowing down

Minor Stops  
Speed Losses  
This Photo by Unknown Author is licensed under CC BY-SA-NC
Making bad products

Scrap  
Rework  

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Who developed TPM?

 George Smith (a founder of the Marshall Institute, an

asset management consulting firm) was invited to
Japan in the 1950’s to teach the preventive
maintenance.
 His interpreter was Seiichi Nakajima, an engineer
from Japan, developed TPM in the early 1970s from
productive maintenance– a hybrid of preventive and
predictive maintenance and several engineering
methods carried out through employee involvement.

https://www.marshallinstitute.com/about-us/

Where did TPM start?

 TPM was developed in 1969 in Japan at Nippon Denso

Co. under Nakajima’s (of the Japan Institute of Plant
Maintenance) leadership.
 Nippon Electrical Components Co. split from Toyota
Motor Co. in 1949 and changed its name to Nippon
Denso Co. As of 2022 Toyota owned 25% of Denso’s
shares.
 Denso (new name) is the 2 nd largest automobile parts
manufacturer in the world.
https://www.efficientplantmag.com/2015/06/remembering-the-father-of-tpm/
https://www.denso-technic.com/72-years-of-success-the-history-of-denso
https://www.statista.com/topics/6822/denso/#topicOverview

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