Professional Documents
Culture Documents
Introduction To TPM
Introduction To TPM
Introduction To TPM
Lean Foundations
Continuous Improvement Training
Learning Objectives
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TPM – The Need
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TPM – The Philosophy
TPM aims at using equipment to its maximum
and aids in reducing Life Cycle Costs (LCC)
In other words - going all out to eliminate the
Losses (Waste) caused by the equipment
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TPM - The Six Major Losses (Waste)
Downtime Losses
– (1) Equipment failures
– (2) Set-up and adjustments
Speed Losses
– (3) Idling and minor stoppages
– (4) Reduced speed (actual operating
vs. designed)
Defect Losses
– (5) Defects in process
– (6) Reduced yield between start of
production and stable production
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OEE Formulas
Loss Measure Formula Metric
1. Unexpected Availability Load – Down Time x 100%
Eq. Breakdown
=
Load Time
2. Set-up &
adjustments
] example: 460 min – 60 min = 87%
460
The Theoretical Cycle
3. Idling and Efficiency
minor stoppages
= Time x Processed Qty
x 100%
4. Reduced
speed
] example:
Operating Time
0.5/ unit x 400 units = 50%
400 minutes
400 – 8 = 98%
example:
400
Overall Equip.
.87 x .50 xfreeleansite.com
.98 = 46.2 %
Effectiveness:
OEE Pareto Analysis by Loss Category
Overall
Equipment
Effectiveness
OEE Loss Effects.
120
Loss
100 1&2
% time available
80 Loss
3&4 Loss
60 5&6
46.2 % OEE
40
20
Material Losses
– Losses in yield due to ‘inherent waste’ (cut-off
stock, set-up pieces, prototype, etc)
– Energy losses such as electricity, gas, and
water when machinery is not doing value-
added work
– Idling losses due to inadequate sensors and
product buildup on conveyors and chutes
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Best Practices
World-Class Goals (A TPM “Vision”)
Before After
Availability 87% > 90%
Performance Efficiency 50% > 95%
Ratio of Quality (Yield) 98% > 99%
Overall Eq. Effectiveness 42.6% > 85%
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TPM – Operational Goals (Qualitative)
Cost Reductions
– Actual and to be reduced
– Energy savings
– Maintenance
Equipment Efficiencies
– Zero failures (ultimate goal)
– MTBF (mean time between failures)
– MTTR (mean time between repairs)
– Idle Time
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TPM – Operational Goals, cont.
(Quantitative)
Safety
– Zero accidents
Quality
– Zero failures
– Zero complaints
Education
– Hours of training/ number of sessions
– Number of KAIZEN projects
– Number of Suggestions
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TPM – Definition of ‘Total’
Total Effectiveness
– Reduction in losses of all equipment to optimize its
effectiveness and improve costs
Total Maintenance
– Involves the whole maintenance system inclusive of
equipment manufacturer, equipment engineering, and
equipment user to improve maintainability
Total Participation
– Everyone has a role to make TPM work
– Management to set policy
– Middle management, staff to support and lead
– Maintenance to maintain and train
– Operators to take on new maintenance challenges
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TPM – Role of Maintenance Function
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TPM – Role of Operator Function
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TPM – Autonomous Maintenance
Definition:
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7 Steps to Autonomous Maintenance
“Kick-off” program
Closely aligned with 6S (5S + 1)
Management and Staff show commitment
Clean, Sand and Paint
Identify sources of defects:
– Gauge hidden
– Limit switch buried in debris
– Crack in Housing
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7 Steps to Autonomous Maintenance
Step 2 – Stop sources of defects (External)
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7 Steps to Autonomous Maintenance
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7 Steps to Autonomous Maintenance
Step 4 – Overall Checkup (Internal)
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7 Steps to Autonomous Maintenance
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7 Steps to Autonomous Maintenance
Step 7 – “All out” Autonomous Management
Process never ends
– Metrics
– Audits
RELIABILITY
Driven by Pareto Analysis to prioritize
Data based
Reduction in MTTR
Increase in MTBF
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Reliability Maintenance
Meantime to Failure (Goal is to maximize)
– Machine Breakdown
– Tool Breakdown
– Part Failure
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TPM – Breakout Activity
With a small group,
With regard to Maintenance - Decide at least 3
new improvements to put into place in your
area.
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The Lean Enterprise
Introduction to TPM – Total Productive Maintenance
Lean Foundations
Continuous Improvement Training