Total Productive Maintenance

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Welcome to our meeting
today we will have a disscusion about
Total Productive Maintenance
roles will be played by
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• Laura Dietrich Maintenance Manger
• Antoinette Lockett Plant Manger
• Waseem Manzoor Quality Manger
• Xiaoyan Liu Production Manger

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Meeting Agenda

• Understanding Downtime -Group
• Major Losses of TPM -Antoinette Lockett
• Planned Downtime Losses -Xiaoyan Liu
• Unplanned Downtime Losses -Laura Dietrich
• Reduce Speed Losses-
• Poor Quality Losses -Waseem Manzoor
• Total Productive Maintenance
• What is TPM -Antoinette Lockett
• Breakdown of TPM -Laura Dietrich
• TPM History -Laura Dietrich
• TPM Evolution
• Goal of TPM -Antoinette Lockett
• Three Principles of Prevention

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Meeting Agenda Cont.

• TPM-8 Pillars-Laura Dietrich
• Kick off TPM
• Launching TPM- Preparatory Stage-Antoinette
  Lockett
• Autonomous Maintenance- Xiaoyan Liu
• Equipment Management Life Cycle- Xiaoyan Liu
• TPM Implementation-Waseem Manzoor
• Launching TPM- Stabilization-Waseen Manzoor
• Eliminating Equipment Losses-Laura Dietrich
• Improvement Goals for Chronic Losses-Laura
  Dietrich
• Overall Equipment Efficiency
• What is OEE-Xiaoyan Liu
• OEE Factors-Xiayon Liu
• Calculating OEE-Waseem Manzoor
• TPM Benefits-Xiaoyan Liu

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Understanding Downtime
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MAJOR LOSSES
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Planned Downtime losses

• Start-ups
• shift changes
• coffee and lunch breaks
• planned maintenance shutdowns

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Unplanned Downtime Losses

• Equipment breakdown
• Changeovers
• Lack of material

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Reduced Speed Losses

• Idling and minor stoppages
• Slow-downs

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Poor Quality Losses

• Process non-conformities
• Scrap

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TPM
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What is Total Productive Maintenance?

• TPM is a plant improvement methodology which
  enables continuous and rapid improvement of the
  manufacturing process through use of employee
  involvement, employee empowerment, and
  closed-loop measurement of results

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Breakdown of TPM

• TOTAL All encompassing by maintenance and
  production individuals working together
• PRODUCTIVE Production goods and services that
  meet or exceed customers expectations
• MAINTENANCE Keeping equipment and plant in as
  good as or better than the original conditions at
  all times

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TPM - History

• Productive maintenance (PM) originated in the
  U.S. in late 1940s early 1950s
• Japanese companies modified and enhanced it to
  fit the Japanese industrial environment
• The first use the term TPM was in 1961 by
  Nippondenso, a Japanese auto components
  manufacturer
• Seiichi Nakajima head of JIPM, one of the
  earliest proponents, known as the Father of TPM

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TPM - Evolution

• Breakdown maintenance
• Preventive maintenance (PM)
• Productive maintenance
• Total productive maintenance

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Goals of TPM

• 1. Aims at getting the most effective use of
  equipment
• 2. Builds a comprehensive PM system
• 3. Brings together people from all departments
  concerned with equipment
• 4. Requires the support and cooperation of
  everyone from top managers down
• Promotes and implements PM activities based on
  autonomous small group activities.
• Maintaining Equipment for life
• Encouraging input from all employees
• Using teams for continuous improvement

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Three Principles of Prevention

• Maintenance of normal conditions
• Early discovery of abnormalities
• Prompt response

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TPM 8 PILLARS
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Kick off TPM
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Launching TPM- Preparatory Stage

• Announce top managements decision to introduce
  TPM
• Launch an educational campaign to introduce TPM
• Create an organizational structure to promote TPM
• Establish basic policies
• Form a master plan for implementing TPM

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Launching TPM- Preliminary Implementation
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Launching TPM- TPM Implementation

• Improve the effectiveness of each critical piece
  of equipment
• Set up and implement autonomous maintenance
• Establish a planned maintenance system in the
  maintenance department
• Provide training to improve operator and
  maintenance skills
• Develop an early equipment management program

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Launching TPM- Stabilization

• Perfect TPM implementation and raise TPM levels

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Eliminating Equipment Losses
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Improvement Goals for Chronic Losses
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OEE
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What is OEE

• OEE (overall equipment efficiency) is a best
  practices way to monitor and improve the
  efficiency of your manufacturing processes
• machines
• manufacturing cells
• assembly lines

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OEE Factors

• Plant Operating Time
• Planned production time
• planned downtime ie. breaks
• Availability
• downtime losses
• Performance
• Speed losses
• Quality
• Quality losses

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World Class OEE
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Calculating OEE

• Availability Operating time/planned production
• Performance Ideal Cycle Time / Total Pieces
  or
• (total pieces / Operating time)/Ideal Run time
• Quality Good Pieces / Total Pieces
• OEE Availability X Performance X Quality

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Example OEE Calculation
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Availability Operating time Planned
production time

• 373 minutes / 420 minutes
• 0.8881 (88.81)

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Performance (Total pieces /Operating time)
Ideal Run Time

• (19,271 pieces/373 minutes)/60 pieces per
  minute
• 0.8611 (86.11)

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Quality Good Pieces Total Pieces

• 18,848 / 19,271 pieces
• 0.9780 (97.80 )

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OEE Availability X Performance X Quality

• 0.8881 X 0.8611 X 0.9780
• 0.7479 (74.79)

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TPM BENIFITS
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TPM - Benefits

• Improved equipment eliminates the root cause of
  defects
• Defects are prevented through planned maintenance
• Preventive maintenance costs are reduced as
  equipment operators conduct autonomous
  maintenance
• Improved equipment designs ensure that new
  equipment naturally produces fewer defects
• Simplified products designs and a redesigned
  process produce with few defects
• Engineers, technicians and managers are trained
  in maintenance and quality

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TPM - Benefits

• (Japanese TPM Prize winners during 1982-1984)
• Equipment failures reduced from 1,000/month to
  20/month
• Quality defects reduced from 1.0 to 0.1
• Warranty claims reduced by 25
• Maintenance costs reduced by 30
• WIP decreased by 50
• Productivity improved by 50. (Patterson
  Fredendall, 1995)

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TPM Success stories

• USPS Albany, New York annual save of 86,000
  could save 4.5 million if applied nationwide
• Yamato Kogyo Corp., Japan
• - productivity up by 130,
• - accidents cut by 90,
• - defects reduced by 95,
• - employee suggestion rate increased by over
  300

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