TPM Third Country TC-print 1

Total Productive Maintenance

(TPM)
Lszl Sos
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 physical
manifestation of the knowledge.
TECHNOLOGY
CAD
Computer Modeling
CNC Machines
Assembling robots
Automatic Control
Automatic store
..
HOW THE TECHNOLOGY
EFFECT THE BUSINESS
Design Easy to sell product
Production Required quality
Operation Low cost
Delivery Short lead time
MAINTENANCE
It makes easy for the technology to perform appropriate effect for business
TPM Third Country TC-print 4
OPERATION UNTIL BREAKDOWN
PREVENTIVE MAINTENANCE
TPM
CONDITION BASED
AGAINST BREAKDOWN
TIME BASED
COMPANY WIDE
DOING 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
PREVENTIVE
MAINTENANCE
(PROFESSIONAL)
WHEN?
HOW?
TIME BASED
CONDITION
BASED
FAILURE
DETERMINATION
OILING
LUBRICATION
CLEANING
PRACTICE
VIBRATION
TRIBOLOGY
TEMPERATURE
ELECTRICAL
RELIABILITY
BASED
MAINTENANCE
TPM
AUTONOMOUS
MAINTENANCE CONTINUOUS
IMPROVEMENT
GENERAL REPAIR
OPERATION
UNTIL
BREAKDOWN
MAITENANCE POLICY
TPM Third Country TC-print 6
TOTAL MAINTENANCE SYSTEM
Professional
maintenance
Autonomous
maintenance
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 of
the 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 of
the employee should be appreciated and/or rewarded.
The targets and features of TPM
TPM Third Country TC-print 10
Operator = Operates the
machine
Maintenance = Maintenance
person +
repair
Engineer = Production
cycle
planning
Conventional maintenance
Daily checking
Observe the abnormality
Cleaning and lubrication
Quality knowledge
Maintenance planning
Planning for easy
maintenance
T
P
M
=
SUPPLEMENTATION OF THE CONVENTIONAL MAINTENANCE
Requirements for the company: high level Production & Quality
Multi qualification
Creativity
Changing 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 added
hours
Defect
loss
Net utilization hours
Speed
loss
Utilization hours
Downtime
loss
Loading hours
Planned
downtime
Theoretical available planned time
Training,
Events
1. Breakdown
2. Set up, adjustment
3. Short stops / Idling loss
4. Reduced speed
5. Quality loss
6. Start-up
Loading hours Downtime
Loading hours
Standard cycle time x Processed unit
Utilization hours
Processed unit Def. u
Processed units
X X
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 of
skill
Poor
Design
Poor operation
conditions
Lack of restoration
of 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 ZERO
AND 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 AFTER
FAILURE
- STUDY THE STRUCTURE AND THE FUNCTION OF THE MACHINE
- BE SURE THAT ALL OF THE DESIRED CONDITIONS WERE
IMPLEMENTED 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
Stoping
t1 t2 t3 t4 t5 t6 t7 t8
TTR1
Performance
Working
TTR2
MTBF =
TBF1 + TBF2
2
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
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TPM Third Country TC-print 21
PROFIT - PRODUCTIVITY - EFFICIENCY
Indicators for
the six big losses
Availability rate
Performance rate
Quality rate
x
x
Loss analysis
B
R
E
A
K
D
O
W
N
Frequency
Analyze
the 5 main
causes of
the machine
breakdown
Length
Analyze
the cause of
the long
repair time
1. Machine basic poor condition
2. Poor operation conditions
3. Lack of restoration of deterioration
4. Poor design
5. Lack of skill
Operational failure
1.Spare part
2.Organiz.
3.Tools
4.Training
occurrence/week min/occurrence x
OEE
1
2
3
4
5
6
DEPLOYMENT
Maintenance failure
Breakdown
Set up, adjust
Short stop
Reduced speed
Quality loss
Start up loss
TPM Third Country TC-print 22
TOTAL PRODUCTIVE MAINTENANCE
MANAGEMENT PILLARS
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TPM