The Lean Enterprise

Introduction to TPM Total Productive Maintenance

Lean Foundations Continuous Improvement Training

Learning Objectives
 
Learn the basic philosophy of TPM Explain OEE and how it contributes to a TPM project, explore OEE components; define and calculate OEE List 6 major components of equipment loss Review and adopt the 7 steps to Autonomous Maintenance

 

freeleansite.com

TPM The Need

   
Process Industry relies heavily on equipment that is integrated and runs continuously When down, losses are costly With lower inventories, machines need to be reliable Machining and Assembly industries becoming more mechanized to save manpower and do difficult jobs More machines to maintain Need to save energy
freeleansite.com

TPM The Philosophy


TPM aims at using equipment to its maximum and aids in reducing Life Cycle Costs (LCC) In other words - going all out to eliminate the Losses (Waste) caused by the equipment TPM improves work activities that deal with Equipment Set-up, Operating parameters, Maintenance, Tear down, Repairs and Breakdowns It specifically aims at the complete elimination of the six major losses while striving for a goal of zero unscheduled downtime

freeleansite.com

TPM - The Six Major Losses (Waste)

 Downtime Losses
(1) Equipment failures (2) Set-up and adjustments

 Speed Losses
(3) Idling and minor stoppages (4) Reduced speed (actual operating vs. designed)

 Defect Losses
(5) Defects in process (6) Reduced yield between start of production and stable production
freeleansite.com

OEE Formulas
Loss
1. Unexpected Eq. Breakdown 2. Set-up & adjustments

Measure
Availability

Formula =

Metric

] ] ]

Load Down Time x 100% Load Time

460 min 60 min 460 The Theoretical Cycle

example:

= 87%

3. Idling and minor stoppages 4. Reduced speed

Efficiency

Time x Processed Qty Operating Time

x 100% = 50%

example:

0.5/ unit x 400 units 400 minutes

5. Defects in Process 6. Reduced Yield

Ratio of Quality Products example:

Processed Amount Amount of Defects Processed Amount 400 8 400

x 100% = 98%

Overall Equip. Effectiveness:

.87 x .50 x .98 = 46.2 %

freeleansite.com

OEE Pareto Analysis by Loss Category

Overall Equipment Effectiveness

OEE Loss Effects.

120 100
% time available
Loss 1&2

80 60 40 20 0
24/ 7 scheduled time

Loss 3&4 Loss 5&6

46.2 % OEE

Availibility Performance (Eff) freeleansite.com

Yield (Quality)

TPM attacks 6 major Losses plus Elimination of other Wastes (Mura, Muri, Muda)

 Operator Time Losses

Manpower losses due to operation time being done more slowly than standard time (Cycle Time > Standard Time)

 Material Losses
Losses in yield due to inherent waste (cut-off stock, set-up pieces, prototype, etc) Energy losses such as electricity, gas, and water when machinery is not doing valueadded work Idling losses due to inadequate sensors and product buildup on conveyors and chutes
freeleansite.com

Best Practices WorldWorld-Class Goals (A TPM Vision)

Before Availability Performance Efficiency Ratio of Quality (Yield) Overall Eq. Effectiveness 87% 50% 98% 42.6% After > 90% > 95% > 99% > 85%

freeleansite.com

TPM Operational Goals (Qualitative)

         
Increase number of suggestions Improve level of teamwork of shop floor Improve cross-functional teamwork Establish maintenance throughout the total equipment life cycle People maintain their own equipment Machines available for just-in-time (JIT) application Improve machine availability Improve working environment (6S) Improve Corporate culture and image Improve Business performance
freeleansite.com

TPM Operational Goals (Quantitative)


Cost Reductions Actual and to be reduced Energy savings Maintenance Equipment Efficiencies Zero failures (ultimate goal) MTBF (mean time between failures) MTTR (mean time between repairs) Idle Time

freeleansite.com

TPM Operational Goals, cont. (Quantitative)


Safety Zero accidents

Quality Zero failures Zero complaints

Education Hours of training/ number of sessions Number of KAIZEN projects Number of Suggestions
freeleansite.com

TPM Definition of Total

 
Total Effectiveness
Reduction in losses of all equipment to optimize its effectiveness and improve costs

Total Maintenance
Involves the whole maintenance system inclusive of equipment manufacturer, equipment engineering, and equipment user to improve maintainability

Total Participation
Everyone has a role to make TPM work Management to set policy Middle management, staff to support and lead Maintenance to maintain and train Operators to take on new maintenance challenges
freeleansite.com

TPM Role of Maintenance Function

   
Provides technical support for autonomous maintenance done by operators Restores deteriorated equipment through checks, inspections, and overhauls Identifies Design weaknesses and improves the equipment to error-free function (via poka-yoke) Improves technical maintenance skills for checks, inspections, and overhauls

freeleansite.com

TPM Role of Operator Function

   
Maintains basic condition (cleaning and lubrication) Maintains proper condition and standards for equipment usage Partially restores deterioration Basic skill levels in: Changeover and set-up Reduction of minor stoppages and adjustments
freeleansite.com

TPM Autonomous Maintenance Definition:

 Operations maintains its own equipment  Utilize 7-step plan*

(*Source: Japan Institute of Plant Maintenance)

freeleansite.com

7 Steps to Autonomous Maintenance

Step 1 Initial clean-up (External)

    

Kick-off program Closely aligned with 6S (5S + 1) Management and Staff show commitment Clean, Sand and Paint Identify sources of defects:
Gauge hidden Limit switch buried in debris Crack in Housing

freeleansite.com

7 Steps to Autonomous Maintenance

Step 2 Stop sources of defects (External)
Ask why ? five times Replace parts with cracks Replace worn seals Teach Operators how to modify equipment Conduct Set-up Workshops; Practice Set-ups Modify Equipment for easier checking and to eliminate sources for debris and contamination
Guards Chip removal Acrylic covers to see V - belts and moving parts
freeleansite.com

7 Steps to Autonomous Maintenance

Step 3 Standards Formulation

Standards for clean-up and checking

What equipment should be cleaned and checked? What points should be checked? Who should check? What check sheet should be used? How to react to changes.

Standards are to capture what has been learned in steps 1 and 2

freeleansite.com

7 Steps to Autonomous Maintenance

Step 4 Overall Checkup (Internal)

Leaders (1st line Supervisors) trained

Hydraulics Air Pressure Electrical/ Electronics Lubrication Mechanical

 

One point lessons developed (Visual Management) Team up Engineers, Maintenance, and Operators Tear down equipment Analyze defects Present findings
freeleansite.com

7 Steps to Autonomous Maintenance

Step 5 Autonomous Checkup

Develop Standards for routine internal checkup

Hydraulics Air Pressure Electrical/ Electronics Lubrication Mechanical

Operator executes routine checks

freeleansite.com

7 Steps to Autonomous Maintenance Step 6 Orderliness and Tidiness

 Improve on Supplier Activity

Spare parts supply partners Spare parts stores Spare parts inventory

 Improve on Tool Activity

Tool Crib orderliness Tools frequently used at work station
(refer to Visual Management/ Visual Control)
freeleansite.com

7 Steps to Autonomous Maintenance

Step 7 All out Autonomous Management

Process never ends Metrics Audits Each process post Result* (actual) against Goal (target) Zero lost time accidents Zero Defects Zero Breakdowns Zero set-up time or at least < 10 minutes
Practice Quick Changeovers/ SMED (see separate module) * Utilize Accountability Meetings (see separate module)
freeleansite.com

TPM Kaizen and Reliability Maintenance

KAIZEN (see separate module)

     

SWAT Team approach to major problems (Focus improvement effort around 6 big Losses) Reduction in Changeover/ Set-up time

RELIABILITY
Driven by Pareto Analysis to prioritize Data based Reduction in MTTR Increase in MTBF
freeleansite.com

Reliability Maintenance

Meantime to Failure (Goal is to maximize)
Machine Breakdown Tool Breakdown Part Failure

Meantime to Repair (Goal is to minimize)

Diagnose problem Correct problem Set up Machine to make good parts Spare parts control

Analyze using Statistical Tools

Reliability Measures Problem Solving Tools Vibration Analysis Tools
freeleansite.com

TPM - Reliability Kaizen Examples

1) Tool cutting Tip (Nissan Motors) Life Cycle = 45 pieces
KAIZEN #1 Vibrational analysis to optimize rotational speed. Life cycle = 132 pieces. KAIZEN #2 Analysis of wear pattern to optimize tool geometry. Life cycle = 305 pieces.

2) Tool cutting (Toyota Motors) Tool expensive and takes long time to set up
KAIZEN #1 Reduced set-up time from 15 minutes to less than 10 seconds. KAIZEN #2 Studied correlation between life of tool and number of cuts between sharpening increase life of tool five-fold.
freeleansite.com

Planned Maintenance Best Practices  Maintenance department primarily responsible  Re-adjustment of Machines to bring back to
 

original state Feedback information to Maintenance Prevention Group Collection of Reliability Data
MTBF MTTR Finding and coping with chronic defects Machine accuracy control (calibration) Schedule boards (Visual Management) Control of
Spare Parts Lubrication Vibrational Analysis
freeleansite.com

Maintenance Prevention Best Practices

          
New equipment design integrated w/ New Product Introduction (NPI) efforts Input from Reliability Maintenance Input from Preventative Maintenance Input from KAIZEN activities Life Cycle Costing Design reviews (Operators, Supervisors, Engineers) Assembly at Supplier Final Inspection at Supplier Maintenance and Operations Manual preparation Safety Issues visible, aware and worked Preventative Maintenance Schedule posted, adhered to
freeleansite.com

TPM Summary

 Total Productive Maintenance is about:

improved equipment performance
increased equipment availability increased equipment FPY (first pass yield) or also called FTT (first time through) reduced emergency downtime increased return on investment increased employee skill levels increased employee empowerment
freeleansite.com

TPM Breakout Activity

With a small group, With regard to Maintenance - Decide at least 3 new improvements to put into place in your area. Decide at least 3 new measures/ metrics to adopt to sustain your Maintenance activities. Present your plan to Supervision.

freeleansite.com

The Lean Enterprise

Introduction to TPM Total Productive Maintenance

Lean Foundations Continuous Improvement Training