Professional Documents
Culture Documents
Blue 7 TPM Part 1 of 2
Blue 7 TPM Part 1 of 2
TOTAL
PRODUCTIVE
MAINTENANCE
TPM: Six Major Losses
Downtime Losses:
1. Equipment failures or breakdowns.
2. Delayed setups and increased adjustments.
Speed losses
3. Jams, work-piece caught on an obstruction or component.
Sensors trips and shuts machine down due to overloads,
quality problems (mistake proofing).
4. Reduced speed, optimal speed unknown and higher speeds
cause problems.
Defect Losses
5. Process defects leading to scrap and rework, deteriorating quality.
6. Reduced yields from machine startup to stabilize production.
How Do They Change the Culture?
Why?
TPM:
Begin process with 5-S Program
Sort
Set in Order
Shine
Standardize
Sustain
Safety
Maintenance
Traditional vs. Lean Manufacturing
1-Only performed as needed. 1-Continual and effective.
Corrective Maintenance
+ Preventive Maintenance
+ Predictive Maintenance
= Continuous Improvement In Maintenance
Or: Total Productive Maintenance
Reactive Maintenance
Maintenance Planning
Prioritize departments, start with critical areas
or departments.
Rank equipment as critical or non critical.
Establish through Impact teams preventative
maintenance requirements per day, per week,
per month, per year.
Issue work orders/check off sheets, close out
work orders and check off sheets.
Plan major maintenance projects.
Preventive Maintenance includes:
Oil Analysis
Vibration Analysis
Ultrasonic
Fluid Contamination Analysis
TPM System
Total Productive Maintenance
Coolant &
Hydraulic
Fluids on
Exterior
Air &
Lubrication in
Hard-to-reach
location
Operator Maintenance
Step
7 Autonomous Control
Step
6 Standardization
Step 5
Autonomous Inspection
S t ep
4 General Inspection
Step
3
Cleaning, Lube & Inspection Standards
Step 2
Eliminate Sources of Problems
Step
1
Hands-on Initial Cleaning
Campbell Machine
Operator Maintenance
Step 2 – Eliminate Sources
Main Actions Before
Corrections and improvements
listed up during step #1 Hard
to inspect
Objectives
Safety and environmental
concerns resolved
Reducing time required for
cleaning, inspecting and
lubricating
Easy
Repairing all outstanding to inspect
abnormalities
After
Operator Maintenance
Step
7 Autonomous Control
Step
6 Standardization
Step 5
Autonomous Inspection
S t ep
4 General Inspection
Step
3
Cleaning, Lube & Inspection Standards
Step 2
Eliminate Sources of Problems
Step
1
Hands-on Initial Cleaning
Preventive Maintenance
- Training
BEFORE AFTER