3. TPM – The Big Picture
Involving employees to maintain
their own equipment
Emphasizing proactive
maintenance
Emphasizing preventive
maintenance
• Improved production
• Fewer breakdowns
• Fewer stops
• Less defects
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4. TPM – The Big Picture
A key tool in Lean Manufacturing
Holistic approach to equipment maintenace
TPM is a team based maintenace
TPM is a never ending journey of continuous improvement
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6. Objectives of TPM
Establishing a culture to maximize production
effectivenss
Organizing shop-floor system to prevent losses
Involving all the functions of the organization
Achieveing zero losses, breakdowns and defects
TPM
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9. The Eight Pillars of TPM
• Operator feels ownership
• Equipment remains well cleaned
• Identifies emergent issues
Autonomus
Maintenance
• Reduces unplanned stop times
• Maintenance when machine is not in production
• Reduces inventory through control of spare parts
Planned
Maintenance
• Removes root source of defects
• Reduces number of defects
• Reduces cost by catching defects early
Quality
Maintenance
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10. The Eight Pillars of TPM
• Recurring problems are identfied
• Combines the collective talents of a company
to ensure continuous improvement
Focused
Imrpovement
• New equipment reaches planned
performance faster
• Maintenance is simpler and more robust
Early Equipment
Management
• Operators develop skills of maintenance
• Managers know about TPM goals and
principles
Training and
Education
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11. The Eight Pillars of TPM
• Safer workplace
• Fewer accidents, fewer stops
Safety, Health
and Environment
• Extends TPM benefits beyond the plant floor
• Supports production through improved
administration
TPM in
Administration
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12. Roadmap for TPM ImplementationStepOne
Identify
Pilot
Area
Easiest to
improve
Constraint/
Bottleneck
Most
problematic
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13. Roadmap for TPM ImplementationStepTwo
Restore
Equipment
to Prime
Operating
Condition
5S
Autonomous
Maintenance
Inspection
Points
Visibility Set Points
Lubrication
Points
Operator
Training
Create
Checklist
Audit
Autonomous
Maintenance
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14. Roadmap for TPM ImplementationStepThree
Start
Measuring
OEE
OEE stands for Overall Equipment Effectivenss
• Gold standard for measuring manufactruing productivity
• Measuring OEE is a manufacturing best practice
OEE
Availabilty
PerformanceQuality
Factors of OEE
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15. Roadmap for TPM ImplementationStepFour
Address
Major
Losses
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16. Roadmap for TPM ImplementationStepFive
Introduce
Proactive
Maintenance
Techniques
Create Feedback System
Create component log Monthly audit
Maintenance interval
adjustments
Establish Maintenance Intervals
Wear based
Predicted Failure
based
Time based Work order based
Identify Components
Components that wear Components that fail Stress points
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17. Conclusion
By implementing TPM a company benefits by
• Increased equipment uptime
• Increased plant capacity
• Lower maintenance and production costs
• Lower defects
• Enhanced job satisfaction
Profit increased by 16 million USD for an investment of 5 million USD
Engage
employees
Aim for
early
success
Provide
active
leadership
Share
success
stories
Rewards
Continu
ously
improve
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