Total Productive Maintenance (TPM) - JICA Alumnijica-alumni.ro/resurse/tpm.pdf · TPM Third Country...
Transcript of Total Productive Maintenance (TPM) - JICA Alumnijica-alumni.ro/resurse/tpm.pdf · TPM Third Country...
TPM Third Country TC-print 2
OUTLINE
Types of maintenance
Total maintenance system
The six big losses reduce the efficiency
The 5 causes of breakdown
Breakdowns and reliability
The importance of the loss deployment
TPM Third Country TC-print 3
PEOPLE, EQUIPMENT, TECHNOLOGY
In the competitive environment the technology is the physicalmanifestation of the knowledge.
TECHNOLOGY
CADComputer ModelingCNC MachinesAssembling robotsAutomatic ControlAutomatic store…..
HOW THE TECHNOLOGYEFFECT THE BUSINESS
Design Easy to sell productProduction Required quality Operation Low cost Delivery Short lead time
MAINTENANCEIt makes easy for the technology to perform appropriate effect for business
TPM Third Country TC-print 4
OPERATION UNTIL BREAKDOWN
PREVENTIVE MAINTENANCE
TPM
CONDITION BASEDAGAINST BREAKDOWN
TIME BASED
COMPANY WIDEDOING BY THE PRODUCTION &
MAINTENANCE
NO MAINTENANCE, ONLY REPAIR
-1950
1950-
1970-
REPAIR
REPAIR
TYPES OF THE MAITENANCE
164 COMPANIES WON TPM AWARDS FOR THE EXCELENT PLANT MAINTENANCE IN 2003(JIPM Japan Institute of Plant Maintenance)
Breakdown can happen any time
TPM Third Country TC-print 5
BREAKDOWN REPAIR
PREVENTIVEMAINTENANCE
(PROFESSIONAL)
WHEN?HOW?
TIME BASED
CONDITION BASED
FAILUREDETERMINATION
OILING LUBRICATION
CLEANING
PRACTICE
VIBRATIONTRIBOLOGY
TEMPERATUREELECTRICAL
RELIABILITY BASED
MAINTENANCE
TPM
AUTONOMOUSMAINTENANCE CONTINUOUS
IMPROVEMENT
GENERAL REPAIR
OPERATIONUNTIL
BREAKDOWN
MAITENANCE POLICY
TPM Third Country TC-print 6
TOTAL MAINTENANCE SYSTEM
Professionalmaintenance
Autonomousmaintenance
REPAIR
PREVENTIVE MAINTENANCE
CLEANING, LUBRICATION
PAYING ATTENTION TO ABNORMALITY
TPM Third Country TC-print 7
TPM ( TOTAL PRODUCTIVE MAINTENANCE )
TPM is an acronym of Total Productive Maintenance and
its more advanced form Total Productive Management.
TPM combines the American Preventive Maintenance practice and the Japan Total Quality Control.
The result is an innovative system what optimizes the efficiency, prevents machine breakdowns and support the autonomous maintenance in the daily practice.
What is TPM ?
TPM Third Country TC-print 8
TPM ( TOTAL PRODUCTIVE MAINTENANCE )
The scope of TPM
⇒ Reduction of the machine breakdown
⇒ Reduction of the repair time
⇒ Quality improvement
TPM Third Country TC-print 9
TPM ( TOTAL PRODUCTIVE MAINTENANCE )
� TPM target is to maximize the efficient usage of the machine during the whole lifecycle.
� The operation of TPM needs the involvement of all organization units at all level.This motivates the teamwork and the autonomous activity.
� TPM includes the improvement of the operational/maintenance system, the implementation of the good housekeeping, the improvement ofthe problem solving ability to be achieve the “ZERO” breakdown, „ZERO” Accident, „ZERO” defect.
� Top management should prepare an evaluation system.
� Based on the evaluation system the ability and responsibility ofthe employee should be appreciated and/or rewarded.
The targets and features of TPM
TPM Third Country TC-print 10
Operator = Operates themachine
Maintenance = Maintenanceperson +
repair
Engineer = Production cycle planning
Conventional maintenance
Daily checkingObserve the abnormalityCleaning and lubrication
Quality knowledge
Maintenance planningPlanning for easy maintenance
TPM
=
SUPPLEMENTATION OF THE CONVENTIONAL MAINTENANCE
Requirements for the company: high level Production & Quality
Multi qualificationCreativityChanging job
+
+
+
Requirements for the employees
TPM Third Country TC-print 11
THE SIX BIG LOSSES REDUCE THE EFFICIENCY
1! BREAKDOWN
2! SET UP & ADJUSTMENT
3! SPEED LOSS
4! SHORT STOPS, IDELING
5! START UP LOSS
6! DEFECT & REWORK
TPM Third Country TC-print 12
THE 6 BIG LOSSES AND „OEE” AS THE MAIN INDICATOR
Value addedhours
Defectloss
Net utilization hours Speedloss
Utilization hours Downtimeloss
Loading hours Planneddowntime
Theoretical available planned time
Training,Events
1. Breakdown2. Set up, adjustment
3. Short stops / Idling loss4. Reduced speed
5. Quality loss6. Start-up
Loading hours – DowntimeLoading hours
Standard cycle time x Processed unitUtilization hours
Processed unit – Def. uProcessed unitsXX
Overall Equipment Efficiency (OEE)
AVAILIBILITY PERFORMANCE RATE QUALITY RATE
TPM Third Country TC-print 13
THE 5 COUSES OF BREAKDOWNS
Machine basic poor condition
Lack ofskill
PoorDesign
Poor operation conditions
Lack of restorationof deterioration
TPM Third Country TC-print 14
BREAKDOWN PREVENTION
1. GUARANTEE THE BASIC CONDITIONS:
- MACHINE CLEANING AT THE SOURCE OF THE DIRT
- TIGHTENING FIX LOOSENING
- OILING FILLED VOLUME LIST
- STANDARDS CLEANING & LUBRICATION
TPM Third Country TC-print 15
BREAKDOWN PREVENTION
2. KEEPING THE OPERATION CONDITIONS
- DEFINE THE PLANNED CAPACITY AND THE LOAD LIMIT
- OPERATION METHOD STANDARDIZATION
- DEFINITION AND IMPROVEMENT OF THE USAGE CONDITIONS OF THE PARTS & UNITS
- DEFINITION OF THE PIPES & CABLES
- IMPROVEMENT OF THE IMPLEMENTATION INSTRUCTIONS
- PROTECTION AGAINST DUST AND WATER AT THE SLIDING & TURNING PARTS
- GUARANTEE THE ENVIRONMENTAL CONDITIONS IN TERMS OF DUST, TEMPERATURE, HUMADITY AND VIBRATION
TPM Third Country TC-print 16
BREAKDOWN PREVENTION
3. RESTORE THE DETERIORATION
- BIG CHANGES ARE RECOGNISED – SMALL CHANGES (DETERIORATION) SOMETIMES ARE OVERLOOKED BUT CAN MAKE SPORADIC BREAKDOWNS
- DETERIORATION SHOULD BE MONITORED
- THE NEGLECTED ACTIONS MUST BE DONE CLEANING, OILING
TPM Third Country TC-print 17
BREAKDOWN PREVENTION
4. IMPROVE THE MAINTENANCE
- ANALIZE THE BREAKDOWNS
- ESTABLISH A PREVENTIVE MAINTENANCE SYSTEM
- DEFINE STANDARDS FOR THE MAINTENANCE ACTIVITY
- TRAIN THE MAINENANCE STAFF AND OPERATORS
TPM Third Country TC-print 18
BREAKDOWN PREVENTION
5. IMPROVE THE CONSTRUCTION
- IF THE RESTORATION IS NOT ABLE TO REDUCE THE FAILURES TO ZEROAND MAINTENANCE COST WILL INCREASE, IT IS NECESSARY TO CHANGE THE MACHINE DESIGN
- STEPS OF THE DESIGN CHANGING:- UNDERSTAND THE STATE OF THE MACHINE BEFORE AND AFTERFAILURE
- STUDY THE STRUCTURE AND THE FUNCTION OF THE MACHINE
- BE SURE THAT ALL OF THE DESIRED CONDITIONS WEREIMPLEMENTED ON A PROPERLY WAY
- ANALYSE THE CAUSES
- DEVELOPE AN IMPROVEMENT PLAN
- IMPLEMENT THE PLAN AND MONITOR THE RESULT
TPM Third Country TC-print 19
BREAKDOWNS AND RELIABILITY
MTBF indicator Mean Time Between Failures
MTTR indicator Mean Time To Repair
TBF1
Stopingt1 t2 t3 t4 t5 t6 t7 t8
TTR1
Performance
Working
TTR2
MTBF = TBF1 + TBF22
TBF2
DT2
MTTR = TTR1 + TTR2
Time
DT1
2
DT Downtime
TPM Third Country TC-print 20
POINTS OF THE QUICK RESTORATION (After a breakdown occurs)
Information flow
Parts reserve
Parts store
Parts suppliers, service contracts
Storing of the repair tools
Skills training
Placement
Arrangement
Indication
Placement
Arrangement
Indication
Org
aniz
atio
nTT
R
Dow
ntim
e
TPM Third Country TC-print 21
PROFIT - PRODUCTIVITY - EFFICIENCY
Indicators forthe six big losses
Availability rate
Performance rate
Quality rate
x
x
Loss analysis
BREAKDOWN
Frequency
Analyzethe 5 main causes of
the machine breakdown
Length
Analyze the cause of
the long repair time
1. Machine basic poor condition2. Poor operation conditions3. Lack of restoration of deterioration4. Poor design5. Lack of skill
Operational failure
1.Spare part2.Organiz.3.Tools4.Training
occurrence/week min/occurrencex
OEE12
34
56
DEPLOYMENT
Maintenance failure
BreakdownSet up, adjustShort stopReduced speedQuality lossStart up loss