*,,Click to edit Master title style,Click to edit Master text styles,SeClick to edit Master text styles,Second level,Third level,Fourth level,Fifth level,cond level,The Lean Enterprise,Introduction to TPM Total Productive Maintenance,Lean Foundations,Continuous Improvement Training,,Learning Objectives,Learnthebasicphilosophy ofTPM,Explain OEE andhowit contributesto aTPM project,exploreOEEcomponents;define and calculate OEE,List6 major components of equipment loss,Review andadopt the7 steps to Autonomous Maintenance,,TPM TheNeed,Process Industry relies heavily onequipmentthatis integrated and runs continuously,Whendown,losses are costly,Withlowerinventories,machines need tobe reliable,Machiningand Assembly industries becoming more mechanized to save manpoweranddo difficult jobs,Moremachines to maintain,Needto save energy,,TPM The Philosophy,TPM aims at using equipmentto itsmaximumand aids in reducingLife Cycle Costs(LCC),In other words-going all out to eliminate the Losses(Waste)causedby theequipment,TPM improves work activitiesthat deal with Equipment Set-up,Operating parameters,Maintenance,Tear down,Repairs andBreakdowns,It specifically aimsat thecomplete eliminationof the,six major losses while striving for a goal of zero unscheduled downtime,,TPM -The SixMajorLosses(Waste),Downtime Losses,(1)Equipmentfailures,(2)Set-up andadjustments,Speed Losses,(3)Idling andminorstoppages,(4)Reduced speed(actual operating,vs.designed),DefectLosses,(5)Defects inprocess,(6)Reduced yield between start of,production andstableproduction,,OEE Formulas,1.Unexpected Eq.Breakdown,2.Set-up&adjustments,3.Idling andminor stoppages,4.Reduced speed,5.Defects inProcess,6.Reduced Yield,OverallEquip.,Effectiveness:,Availability,example:,Efficiency,example:,Ratio of Quality,Products,example:,Load Down Time,Load Time,460 min,60 min,460,The Theoretical Cycle,Time xProcessed Qty,Operating Time,0.5/unit x 400 units,400 minutes,Processed Amount,Amountof Defects,Processed Amount,400 8,400,x 100%,=,87%,x 100%,=,50%,x 100%,=,98%,=,=,=,.,87 x.50 x.98=46.2%,LossMeasureFormula,Metr,ic,,OEE Pareto Analysis by LossCategory,Overall,Equipment,Effectiveness,Loss,3&4,46.2%OEE,Loss,1&2,Loss,5&6,,TPM attacks 6major“Losses”plusElimination ofotherWastes,(Mura,Muri,Muda),Operator TimeLosses,Manpower losses due to operation time being donemore slowly than standard time(Cycle Time Standard Time),Material Losses,Lossesin yield due to inherent waste(cut-offstock,set-uppieces,prototype,etc),Energylossessuch aselectricity,gas,and waterwhen machinery is not doingvalue-added work,Idlinglossesdue toinadequate sensors and product buildup onconveyors andchutes,,Best PracticesWorld-Class Goals(ATPM“Vision”),BeforeAfter,Availability87%90%,Performance Efficiency50%95%,Ratio of Quality (Yield)98%99%,OverallEq.Effectiveness42.6%85%,,TPM Operational Goals(Qualitative),Increase number of suggestions,Improvelevelof teamwork ofshop floor,Improvecross-functional teamwork,Establish maintenancethroughout the totalequipment life cycle,Peoplemaintain theirown equipment,Machines available for just-in-time(JIT)application,Improvemachine availability,Improveworking environment(6S),ImproveCorporate culture and image,ImproveBusiness performance,,TPM Operational Goals(Quantitative),Cost Reductions,Actualand tobe reduced,Energysavings,Maintenance,Equipment Efficiencies,Zero failures(ultimate goal),MTBF(mean time between failures),MTTR(mean time between repairs),Idle Time,,TPM Operational Goals,cont.(Quantitative),Safety,Zero accidents,Quality,Zero failures,Zero complaints,Education,Hoursoftraining/number of sessions,NumberofKAIZEN projects,NumberofSuggestions,,TPM,Definition of Total,TotalEffectiveness,Reductioninlosses of allequipmenttooptimizeits effectivenessand improvecosts,TotalMaintenance,Involvesthewholemaintenancesystem inclusiveofequipmentmanufacturer,equipmentengineering,andequipmentusertoimprove maintainability,TotalParticipation,Everyonehasarole to makeTPM work,Management to setpolicy,Middlemanagement,stafftosupportandlead,Maintenancetomaintainandtrain,Operatorstotakeonnewma,int,enancechallenges,,TPM,Role of Maintenance Function,Providestechnicalsupportforautonomousmaintenancedone by operators,Restoresdeterioratedequipment throughchecks,inspections,and overhauls,Identifies Designweaknesses andimprovestheequipment to error-freefunction(viapoka-yoke),Improvestechnicalmaintenanceskills forchecks,inspections,andoverhauls,,TPM,Role of Operator Function,Maintainsbasiccondition(cleaningandlubrication),Maintainsproper conditionandstandards forequipmentusage,Partiallyrestoresdeterioration,Basicskilllevelsin:,Changeover andset-up,Reductionofminorstoppages andadjustments,,TPM,Autonomous Maintenance,Definition:,Operations maintainsitsown equipment,Utilize 7-stepplan*,(*Source:JapanInstitute of Plant Maintenance),,7 Steps to AutonomousMaintenance,Step 1,Initial clean-up(External),“Kick-off,”,”program,Closely alignedwith,6S,(5S+1),Management andStaffshow commitment,Clean,SandandPaint,Identi