TPM - Why, What, Where, Who .. etc etc

1. Total Productive Maintenance TPM - Why, What, Where, Who .. Anand Subramaniam

2. 2 “Another flaw in the human character is that everybody wants to build and nobody wants to do maintenance.” - Kurt Vonnegut

3. 3 Highlights TPM – Overview TPM, TQM, 6S TPM Pillars Losses / Waste / 3 Zero

4. TPM - Overview

5. Lean System 5 Peak Performance Pull system / flow production Rapid Changeover / Customer-driven lot size Continuous Waste Reduction Lean Measures 5S Visual Factory Standardised Work T P M Variation reduction / Six Sigma In-Station Process Control Leadership by Example & Commitment Employee Involvement & Mutual Respect

6. Current Challenges High numbers of component parts Lack of innovation / new ideas & change management Huge Losses – high set up, breakdown, defects, adjustment, reduced speed, yield & productivity Low-quality products & services Workforce lack - skills, training, co-ordination, accountability, responsibility Challenges Work place – unsafe, dirty, & untidy Lack of growth potential Lack and / or complicated production procedures Badly designed, outmoded & many "bottleneck” processes High Operational Costs 6

10. Repair, clean, lubricateTPM

11. TPM - What Plant improvement methodology Build quality into equipment maintenance Company wide strategy for equipment, process improvement & a team based effort A Lean Tool to optimise the effectiveness of manufacturing equipment Continuous improvement of manufacturing process using tools of TQM What Closed-loop measurement of results Aka Autonomous Maintenance, where users take time to clean, inspect & carry out basic maintenance on their equipment. Employee involvement, & empowerment 8

13. Less “firefighting” to repair machines

14. Lower operating costs

15. Better able to meet commitments to customers

17. Better cooperation between maintenance, production, and other departments

18. Reduced chance of accidents

20. TPM - Principles Involve everyone & utilise cross-functional teamwork Provide training to upgrade operations & maintenance skills Starts with 5S / Visual Factory Use Overall Equipment Effectiveness (OEE) as a compass for success Improve existing planned maintenance systems Principles Complete elimination of the ‘six major losses’ while striving for a goal of zero unscheduled downtime Reduce life cycle cost 11

21. TPM – Goals Maintaining Equipment for life and Increase production quality Obtain support and cooperation from top managers to all levels Encourage input from all employees Use teams for continuous improvement Goals Empower and increase job satisfaction Build a comprehensive plant maintenance system based on autonomous small group activities Bring together people from all departments concerned with equipment 12

22. 13 TPM - Strategies Initial Control System Planned Mainten-ance System Operator Autono-mous Mainten-ance Loss Elimination TPM Strategies Education & Training 3 Zeros - Defects , Accidents, & Failures

23. TPM - Benefits Improved capacity & higher productivity Reduced emergency downtime Increased employee skill levels and employee empowerment Increased equipment FPY (first pass yield) / FTT (first time through) Preventive maintenance costs reduced as equipment operators conduct autonomous maintenance Benefits Engineers, technicians and managers trained in maintenance and quality Improved equipment design eliminates the root cause of defects Increased return on investment 14

26. TPM & TQM Similarities Employees empowered to initiate action On-going, continuous process improvement Both requires Senior Management commitment Long term outlook, TPM take time to implement & sustain 17

27. TPM & TQM Differences 18

30. Partnership between maintenance & production

32. SafetyTPM & 6S

33. TPM Pillars

34. TPM - 8 Activity Pillars 21 TPM Pillar Autonomous Maintenance Individual Improvement Planned Maintenance Quality Maintenance Education & Training Office TPM Safety, Health & Environment 5S – Initial Phase Management System

35. Aims – Each TPM Activity Pillar 22 Individual improvementactivities Improvement of equipment efficiency via the pursuit of zero loss, and improvement of technical capabilities Eight pillars of TPM activities Establishment of the autonomous maintenance system Training of personnel proficient in equipment and work, and capable of maintenance management Establishment of the planned maintenance system Establishment of the plans and a management system to realise zero failure equipment, and prevent failures Establishment of the initial-phase management system Establishment of systems to shorten the development period, and to enable one-short start up Establishment of conditions for zero failures to prevent defects, and establishment of systems for maintenance and management Establishment of the quality maintenance system Establish office TPM systems to improve efficiency of admin & support Establishment of an efficient office where office work loss is eliminated Establishment of systems to systematically foster personnel proficient in equipment and work Establishment of the systems for education and training Establishment of the systems for safety, health and the environment Establishment of active plants which are safe and secure for workers

36. Losses / Waste

37. Losses / Waste – 6 Major Losses Defect Losses Defects in process Reduced yield between start of production and stable production Down Time Losses Equipment failures Set-up and adjustments Speed Losses Idling and minor stoppages Reduced speed (actual operating vs. designed)

39. Past examples of malfunctions

41. Quality product map

42. # of equipment failures

43. Improvement progress mapThree Zero

44. 26 “All parts should go together without forcing. You must remember that the parts you are reassembling were disassembled by you. Therefore, if you can't get them together again, there must be a reason. By all means, do not use a hammer.” - IBM maintenance manual

45. 27 Good Luck http://www.linkedin.com/in/anandsubramaniam