Total Preventative

Maintenance
 How Regular Maintenance Can Save
Time and Money

With scheduled maintenance With no preventive maintenance

 Change oil  Unexpected breakdowns
 Top off fluids
 Wasted time
 Put air in tires
 Costly repairs

Reliable, efficient operation Frustration!

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 Total Preventative Maintenance (TPM)

 “Total Preventative Maintenance”-- TPM, an activity focusing on total

employee involvement in achieving minimum waste through
maintenance operations
 TPM is a concept that involves all employees. The goal of TPM is to
achieve overall effectiveness of the production system through
employee participation in preventative maintenance activities
 Just as quality is built into the process rather than achieved through
inspections, preventative maintenance is much more desirable than
machine breakdowns

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 Total Preventative Maintenance (TPM)

Where are we today?

 Maintenance staff are busy “fire fighting” and forgoing the required
maintenance work, while production staff assume that machine break-
downs are not their responsibility
 Machines are not maintained to achieve 100 percent “on-demand”
availability for immediate use.
 In order to be competitive in manufacturing, all machine breakdowns
must be eliminated.

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 Establish Overall Equipment
Effectiveness (OEE)

Definition: Is a measure of equipment effectiveness

when equipment is scheduled to run.

EQUIPMENT AVAILABILITY
x
PERFORMANCE EFFICIENCY
x
RATE OF QUALITY

Excludes: Planned Downtime (including planned maintenance)

Includes: Setup Time

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 Setting the OEE Goal

“World Class” companies

achieve an OEE level of 85% after
implementing TPM

Availability: Better than 90%

Performance Efficiency: Better than 95%
Rate of Quality: Better than 99%

OEE: 90% x 95% x 99% = 85%

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The Six Major Losses of OEE

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 Total Preventative Maintenance (TPM)

Factors Leading to Machine Breakdown

 Failure to maintain fundamental machine requirements e.g. housekeeping,

oiling, bolt tightening, etc.

 Failure to maintain correct operating conditions e.g. temperature, vibration,

pressure, speed, torque, etc.

 Lack of Skills e.g., Operator mis-handling / operation, maintenance crew errors

 Deterioration, e.g., of bearings, gears, fixtures, etc.
 Design Deficiency, e.g., materials, dimensions, etc.

It is generally a combination of the above factors that causes

machine breakdowns

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 Breakdown Causes

Grit and Dirt in Lack of, or excessive

moving parts lubrication

Improperly
fitted keys

Water or oil
contamination
Electric Motor
75% of all equipment breakdowns are caused
by contamination and lack of lubrication!
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 Total Preventative Maintenance (TPM)
Traditional Approach
 Machine Breakdown and breakdown
maintenance and replacement of
broken machine parts
 Equipment maintenance is
maintenance's responsibility -- no
operator involvement and ownership
 Maintenance is not scheduled (run to
failure)
Total Preventative Maintenance
 Conditioned-based and preventive
maintenance
 Machine trouble records and Mean Time
Between Failures (MTBF) tracking and
analysis
 Total employee / operator Involvement
 Employee / operator education
 Employee / operator ownership
 Maintenance is scheduled
 “Maintenance is Free”
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 Total Preventative Maintenance (TPM)

• Dramatic results

• Visibly transform the workplace

• Raise the knowledge & skill level in

Production and Maintenance workers

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 Total Preventative Maintenance (TPM)

An Approach to Preventing Machine Breakdowns

What How
 Inspection
Maintain Normal  Cleaning
Machine Conditions  Tightening, etc.
 Maintaining Correct Operating Procedures

 Inspection and use of operator’s sense

Detect Abnormal Conditions
 Use of diagnostic equipment
as Early as Possible Visual Controls

Develop and Implement Counter-

 Ask why, Five Time
Measures to Maintain Normal
 Develop New procedures / Standards
Operating Condition

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 Steps to Implement TPM

1 Determine where to focus

2 Establish Team Ownership
3 Initiate Cleaning, Inspection and Maintenance of Equipment
 Bring machine up to normal operating condition as specified by the OEM.
4 Apply Visual Controls and equipment modifications as needed
5 Create Operator Checksheet
6 Identify Critical Spare Parts and a plan to address them
7 Determine PM plan
8 Establish a team to continually improve TPM activities

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 Clean to Inspect
Inspect to Detect
Detect to Correct
Correct to Perfect
But it Starts with Cleaning
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 Establish Maintenance Plan

• Daily Checklist
- Created by team
- Completed by operator in 5 minutes or less

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 Step 6: Create Critical Spare Parts List

Two conditions that make a repair part critical

 Equipment is likely to fail (history of failure exists)
 We can’t get the part quickly. (within 48 hours)

48 hour rule
“If a critical machinery repair part cannot be supplied
within a 48 hour repair window, it “should” be kept in-
house to facilitate breakdown emergencies. This is
particularly critical for bottleneck equipment”.
 Critical spare parts list for all category A & B equipment

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 Total Preventative Maintenance (TPM)
Laser Welder Output
Good Output
50

45
70% OEE
With PM’s & a
40 TPM Coordinator
in place.
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30 After 5 day Output average

46% OEE Focused
Improvement good grids per day =
25 29 – 44 = 52% increase

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Grids
per day
March-September 2002 October-December 2002 January-February 2003
Time - Months
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 TPM Improves Equipment
Reliability and Life
Start-up Wear-out
Phase Normal Operating Phase Phase
100%

90%
Equipment on TPM
80%

70%
Reliability

60%

50%
Equipment not on TPM
40%

30%

20%

10%

0%
0 1 2 3 4 5 6 7
Years
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 Total Preventative Maintenance - Summary

 The paradigm must shift. Stopping production or scheduling for

machine maintenance should be a welcomed activity. An hour spent
on maintenance will save tens of hours of shutdown due to machine
failure.
 TPM ownership must be at the operations level.
 TPM delivers increased availability of machines.

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