En Introduction to TPM - Objectives and Benefits
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Transcript of En Introduction to TPM - Objectives and Benefits
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©2008 Productivity Inc. All Rights Reserved
Introduction to TPM – Objectives and Benefits
September 29, 2008
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The Five Pillars of TPM The Five Pillars of TPM TPM TPM TPM
Aut
onom
ous M
aint
enan
ce
Mai
nten
ance
Pro
cess
Impr
ovem
ent
Syst
emat
ic E
quip
men
t Im
prov
emen
t
Tra
inin
g &
Ski
ll D
evel
opm
ent
Ear
ly E
quip
men
t Man
agem
ent
Cross-Functional, Team-Based Improvement Activities
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Textbook Definition
“TPM is a plant improvement methodology which enables continuous and rapid improvement
through use of employee involvement, employee empowerment, and closed-loop measurement of
results.”
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TPM Implementation – Nakajima’s 12 Steps1. Announce Top Management’s Decision to Introduce TPM2. Launch Educational Campaign3. Create Organizations to Promote TPM4. Establish Basic TPM Policies and Goals5. Formulate a Master Plan for TPM Development6. Hold TPM “Kickoff”7. Improve Equipment Effectiveness8. Establish an Autonomous Maintenance Program for Operators9. Set-up a Scheduled Maintenance Program for the Maintenance
Department10. Conduct Training to Improve Operation and Maintenance Skills11. Develop Initial Equipment Management Program12. Implement TPM Fully and Aim for Higher Goals
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Characteristics of TPM
Optimum relationships between people and equipment/processInvolvement of everyone, from top leadership to shopfloor workersA cross-functional approach, involving all departmentsImplementation through small group teamworkDATA DRIVEN!!!
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Two Types of Teams
Manager
Natural teamNatural team
Manager
Natural teamNatural team
CrossCross--functionalfunctional
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Definition(s)
Note: The DREADED “M” word is not used!!!
So what does maintenance mean anyway…
Maintenance = The act of maintainingMaintain = To keep in a state of order. To keep in
due (rightful, proper, fitting) condition, operation, or force; keep unimpaired.
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Definition(s) cont…Fix and Repair = Maintenance
HOZEN (Maintenance in Japanese) = Maintaining and preserving perfection through Asset Management.
TPM = Total Productive ManagementTPM = Total Productive Manufacturing
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TPM Goals
Zero accidents
Minimum life cycle cost
Zero unplanned downtime
Zero speed losses
Zero defects
Zero waste!
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Results
Overall Equipment Effectiveness (OEE) Improved
Mean Time Between Failure Improved
Mean Time To Repair Improved
Etc…
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Actual “GREEN” Results$60K/ Month Facilities Maintenance Savings
$700K Annual Savings “Other-than-hazardous-waste”
• TPM Process applied to facilities maintenance activities
Plant Air System
Plant Lighting during peak Kilowatt usage
Plant Start-up/Shut-down Procedures
Waste Water Treatment System
Note: Above results since 1998
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TPM Is a Paradigm Shift
Old Attitude“I operate, you fix”
“I fix, you design”
“I design, you operate”
Old Attitude“I operate, you fix”
“I fix, you design”
“I design, you operate”
TPM Attitude“We are all responsiblefor our equipment,our plant, andour future”
TPM Attitude“We are all responsiblefor our equipment,our plant, andour future”
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Training and Skill Development
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Why Training and Skill Development
Operators and Maintenance: • Should possess the training and skills
necessary to carry out all of the required TPM activities so that they have…
A clear understanding of the criteria for judging normal and abnormal conditionsCan be empowered to strictly enforce condition management rulesThe ability to quickly respond to any and all abnormalities
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Early Equipment Management (EEM) and Maintenance Prevention
(MP) Design
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EEM and MP Design
EEM and MP Design are two methods of making improvements at the earliest possible stage, with the goal of “fix and repair” and defect free equipment.
In other words…Operator/Maintenance friendly equipment through lessons learned on existing equipment and applied to new equipment during the concept, design, and installation phase(s).
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EEM/MP Design Involvement
EEM/MP Design is a team approach. The team should ALWAYS include members from…
Maintenance (hourly)Production (hourly)Engineering/Technical
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Maintenance Process Improvement (MPI)
(Planned, Scheduled Maintenance System)
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MPI Tools and Activities
Well trained/skilled craftspeopleLubrication ManagementPreventive Maintenance systemPredictive TechnologiesDocumentation ManagementEEM/MP Design InvolvementMaintenance Management SystemSpare Parts Management
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The Maintenance Techniques
Preventive Maintenance – preventing breakdownsCorrective Maintenance – improving or modifying equipment to prevent breakdowns or to make maintenance easierMaintenance Prevention – designing and installing equipment that needs little or no maintenanceBreakdown Maintenance – repairing or fixing after breakdowns occur
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Systematic Equipment Improvement
(Improve Equipment Effectiveness)
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SEI
A systematic approach to eliminate waste through analysis of the “6” major losses utilizing cross-functional teams to continuously investigate, test, and implement improvements with a goal of maximizing equipment effectiveness.
DATA DRIVEN PROCESS!!!
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Six Major Losses toEquipment Effectiveness
Failures
Setup/changeover and adjustments
Idling and minor stoppages
Reduced speed
Defects and rework
Startup loss
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How the Losses Reduce Effectiveness
QualityPerf.EfficiencyAvailability
OverallEquipment
Effectiveness= xx
ReducedSpeed
StartupLosses
Minor Stopsand Idling
Adjustmentsand Set-Ups
EquipmentFailures
Rejects andDefects
6 MajorLosses
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Autonomous Maintenance
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What IsAutonomous Maintenance?
A collaborative team activity involving production, maintenance, and engineeringAn approach that• develops operating and maintenance skills• strengthens communication and cooperation
A series of activities implemented in well-defined developmental steps
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Seven Steps ofAutonomous Maintenance
1. Conduct initial cleaning/inspection
2. Eliminate sources of contamination
3. Establish provisional standards
4. Develop general inspection training
5. Conduct general inspections
6. Improve workplace management and control
7. Participate in advanced improvement activities
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Cross-Functional Team Activity
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Zero Breakdown Strategies
Restore equipmentMaintain basic equipment conditionsAdhere to standard operating proceduresImprove operator maintenance skillsDon’t stop at emergency fixesCorrect design weaknessesStudy breakdowns relentlessly
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“Button-pushers” to Process Owners
“Firefighters” to Maintainers