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TPM Implementation Strategy

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How to sustain TPM implementation?

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TPM Implementation Strategy

  1. 1. TPM Implementation Strategy<br />How to sustain TPM implementation?<br />Anand Subramaniam<br />
  2. 2. 2<br />“The nicest thing about standards is that there are so many of them to choose from.” <br />- Ken Olsen<br />
  3. 3. TPM - Implementation<br />3<br /><ul><li>Announcement by Management about TQM introduction
  4. 4. Introductory education campaign for workforce
  5. 5. Set up TPM – committee, working system, targets etc
  6. 6. Establish basic TPM policies and goals
  7. 7. Preparation and formulation of a master plan </li></ul>Planning<br />Kick-Off<br />Invite stakeholders - define problem, roadmap<br /><ul><li>Put plan into action by engaging with stakeholders
  8. 8. Develop an equipment & an autonomous maintenance program including tasks sequence, manage change etc
  9. 9. Improve skills of production & maintenance personnel
  10. 10. Develop evaluation criteria</li></ul>Implement<br />Sustain<br /><ul><li>Develop standard operating procedures & sustain TPM</li></li></ul><li>Roles<br />4<br />Operator<br /><ul><li>Maintains basic condition (cleaning and lubrication)
  11. 11. Maintains proper condition and standards for equipment usage
  12. 12. Partially restores deterioration
  13. 13. Basic skill levels in:
  14. 14. Changeover and set-up
  15. 15. Reduction of minor stoppages and adjustments</li></ul>Maintenance<br /><ul><li>Provides technical support for autonomous maintenance done by operators
  16. 16. Restores deteriorated equipment through checks, inspections, and overhauls
  17. 17. Identifies Design weaknesses and improves the equipment to error-free function (via poka-yoke)
  18. 18. Improves technical maintenance skills for checks, inspections, and overhauls</li></li></ul><li>Shift in Attitudes<br />5<br />Conventional<br />TPM<br />Operator<br />Maintenance<br />Equipment Improvement Teams <br />Maintenance<br />Operator<br />I Use<br />I Fix & Maintain<br />We Fix & Maintain<br />
  19. 19. Implementation Team<br />6<br />EIT<br />EIT<br />EIT<br />TPM<br />Advisory<br />Team<br />Mgmt<br />EIT<br />EIT<br />EIT<br />EIT = Equipment Improvement Teams <br />
  20. 20. Team Responsibilities <br />7<br />Advisory<br /><ul><li>Guide & champion TPM implementation
  21. 21. Assess current equipment OEE and develop a process for measuring the “6 big” losses
  22. 22. Develop a TPM master plan
  23. 23. Set plant-wide standards for TPM implementation
  24. 24. Monitor and evaluate progress
  25. 25. Serve on EIT’s</li></ul>EIT<br /><ul><li>Return equipment to near new condition
  26. 26. Investigate and reduce the “big 6” equipment losses
  27. 27. Transfer routine maintenance skills to operators
  28. 28. Set standards for routine maintenance and inspections by operators
  29. 29. Organise the work area for more effective/efficient maintenance</li></li></ul><li>Shift in Emphasis<br />8<br />Before TPM<br />After TPM<br />Breakdown<br />Breakdown<br />Planned Repair<br />Planned Repair<br />Plant Maintenance<br />Plant Maintenance<br />Predictive<br />Autonomous<br />
  30. 30. TPM – Qualitative Goals<br />Improve working environment (6S)<br />Increase number of suggestions<br />Improve Corporate culture and image<br />Improve machine availability<br />Improve cross-functional teamwork<br />Qualitative<br />Establish maintenance throughout the total equipment life cycle<br />Increase worker satisfaction<br />Improve Business performance<br />9<br />
  31. 31. TPM – Quantitative Goals<br /># of training sessions<br />Zero failures, MTBF (mean time between failures), MTTR (mean time between repairs), Idle Time<br /># of suggestions<br />Zero Accidents<br />Quantitative<br /># of Kaizen Projects<br />Zero Complaints<br />Cost Reductions via energy savings, maintenance<br />10<br />
  32. 32. TPM – Sustainability<br />Cleaning, inspection, & lubrication standards<br />Audit results<br />Workplace organisation standards<br />Team charter<br />Trend charts for each of the big 6 losses<br />Visual Activity Boards<br />Inspection reports<br />Team activities, goal, schedule, and progress<br />Before and after photos<br />11<br />
  33. 33. Implementation – Success Criteria<br />Led by work teams<br />Cooperation between all departments<br />Maintenance understanding and support<br />TPM activities become part of the daily routine<br />12<br />
  34. 34. 13<br />“STRATEGY is; A style of thinking, a conscious and deliberate process, an intensive implementation system, the science of insuring FUTURE SUCCESS.” <br />- Pete Johnson<br />
  35. 35. 14<br />Good Luck<br /><br />