This presentation is a collection of PowerPoint diagrams and templates used to convey 24 different TPM Excellence frameworks/models. They include: 1. TPM Excellence Framework 2. 12 Steps of TPM Implementation 3. TPM Implementation Structure 4. TPM Paradigm 5. Machine Loss Pyramid 6. Bathtub Curve 7. 6 Major Equipment Losses 8. Overall Equipment Effectiveness (OEE) 9. Goals of Autonomous Maintenance 10. Autonomous Maintenance Approach 11. 3 Key Tools for AM Activities 12. 7 Steps of Autonomous Maintenance 13. Planned Maintenance Approach 14. 6 Steps of Planned Maintenance 15. Preventive Maintenance Approach 16. 5S Principles 17. 6 Steps of Kaizen 18. Cause & Effect Diagram 19. 5 Whys Technique 20. Visual Management Pyramid 21. Mistake Proofing Process 22. 8 Types of Waste 23. Deming Cycle 24. PDCA Problem Solving Process To download this complete presentation, visit: https://www.oeconsulting.com.sg/training-presentations

1. © Operational Excellence Consulting. All rights reserved.
This presentation is a collection of PowerPoint diagrams and
templates used to convey 24 different TPM Excellence
frameworks/models.
Total Productive Maintenance
(TPM) Frameworks
Diagrams & Templates of Total Productive
Maintenance (TPM) Frameworks & Models

2. © Operational Excellence Consulting. All rights reserved. 2
Contents
1. TPM Excellence Framework
2. 12 Steps of TPM Implementation
3. TPM Implementation Structure
4. TPM Paradigm
5. Machine Loss Pyramid
6. Bathtub Curve
7. 6 Major Equipment Losses
8. Overall Equipment Effectiveness (OEE)
9. Goals of Autonomous Maintenance
10. Autonomous Maintenance Approach
11. 3 Key Tools for AM Activities
12. 7 Steps of Autonomous Maintenance
13. Planned Maintenance Approach
14. 6 Steps of Planned Maintenance
15. Preventive Maintenance Approach
16. 5S Principles
17. 6 Steps of Kaizen
18. Cause & Effect Diagram
19. 5 Whys Technique
20. Visual Management Pyramid
21. Mistake Proofing Process
22. 8 Types of Waste
23. Deming Cycle
24. PDCA Problem Solving Process
NOTE: This is a PARTIAL PREVIEW. To
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The Total Productive Maintenance (TPM) excellence framework
provides a holistic approach to improve capital productivity
TPMintheOffice
Safety,Health&Environment
AutonomousMaintenance
PlannedMaintenance
FocusedImprovement
EarlyEquipment
Management
QualityMaintenance
Education&Training
5S & Visual Management
TPM Goals:
Zero Defects, Zero Breakdowns,
Zero Accidents
Source: Japan Institute of Plant Maintenance (JIPM)
TPM Excellence Framework

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The 12 Steps of TPM Implementation define a systematic approach for
the planning and deployment of TPM activities
TPM Implementation Model
Preparation
Kick-off
Implementation
1. Announcement to introduce TPM
2. Introductory education campaign for the workforce
3. TPM Promotion (special committees)
4. Establish basic TPM policies and goals
5. Preparation and Formulation of a master plan
7. Develop an equipment management program
8. Develop a planned maintenance program
9. Develop an autonomous maintenance program
10. Increase skills of production and maintenance personnel
12. Perfect TPM implementation and raise TPM levelsStabilization
11. Develop early equipment management program
6. Invite customers, affiliated companies and subcontractors
Source: Seiichi Nakajima

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The TPM Implementation Structure provides guidance on how to set
up an organization for TPM governance
TPM Implementation Structure
TPM
Responsible
(Plant Manager)
Focused
Improvement
Autonomous
Maintenance
Education &
Training
Planned
Maintenance
Safety, Health
& Environment
Early
Equipment
Management
Office
TPM
Quality
Maintenance
TPM
Promotion
Office

6. © Operational Excellence Consulting. All rights reserved. 6
TPM is a paradigm shift towards teamwork and collaboration between
Production and Maintenance departments
Old Attitude TPM Attitude
I use I maintain &
I fix
We maintain
Maintenance Operator MaintenanceOperator
TPM Paradigm

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The Machine Loss Pyramid underscores the philosophy of TPM – the
need to listen and watch for anomalies and taking action before the
breakdown
Source: Adapted from Heinrich’s Law on Safety
The Machine Loss Pyramid
1
10
30
Hundreds
Breakdown
(function loss)
Minor Stoppage
(function reduction)
Minor Failures
(no function reduction)
Hidden Failures
(no function reduction)
Motor burns out
Motor overheating
Vibration causes bearing
deterioration
Lose nuts and bolts
Example

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The useful life of equipment can be extended by a preventive
maintenance program as part of a holistic TPM framework
Time
Infant
Mortality
Failures
Useful Life Failures
(Constant Failure Rate)
Wear-Out
Failures
FailureRate
0
TPM extends useful
life of equipment
Overview of TPM
The Bathtub Curve

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Overall Equipment Effectiveness (OEE) can be improved by
eliminating the six major equipment losses
Overall Equipment
Effectiveness
Availability
Breakdowns
Setups &
Adjustments
Performance
Reduced Speed
Minor Stops & Idling
Quality
Defects &
Rework
Startup & Yield Loss
Six Big Losses
Source: Japan Institute of Plant Maintenance (JIPM)
Six Major Equipment Losses

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The Overall Equipment Effectiveness (OEE) is a measure of how well
a manufacturing operation is utilized compared to its full potential
Source: Japan Institute of Plant Maintenance (JIPM)
Overall Equipment Effectiveness (OEE)
Six Big Losses
Downtim
e
Losses
Quality
Losses
Speed
Losses
Fully
Productive
Time
Net Operating
Time
Planned Production Time
Operating Time
Equipment
Average total operating loss
30-50%
Breakdowns
Setups &
Adjustments
Reduced
Speed
Minor Stops &
Idling
Defects &
Rework
Startup &
Yield Loss
Breakdowns per machine
(stopped longer than 10 mins)
– less than once a month
Setup/adjustment time – less
than 10 mins
Achieve ideal cycle times
(design speed); increase 15%
or more
Minor stoppages and idling per
machine – under 10 mins
Rate (including products to be
reworked) – less than 0.1%
Startup yield – 99% or more of
lot
Ideal Cycle Time x Total Pcs
Operating Time
Good Pieces
Total Pieces
Operating Time
Planned Production Time
Availability
Quality
Performance
Greater than 90%
Throughput process
- Greater than 99%
Greater than 95%
OEE Factors
OEE = Availability x Performance x Quality

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The Check-Act-Plan-Do cycle is the basic approach for Autonomous
Maintenance activities
Source: Adapted from Society for Maintenance & Reliability Professionals
Check
ActPlan
Do
Examine and
expose problems
Counter and
solve problems
Execute and follow
standards and rules
Prevent recurrence
through improvement
Autonomous Maintenance Approach

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The seven steps of AM activities outline a systematic approach for
operators to implement AM on the shopfloor
Seven Steps of Autonomous Maintenance
1. Clean and inspect
2. Eliminate problem sources and inaccessible
areas
3. Draw up cleaning and lubricating standards
4. Conduct general inspections
5. Conduct autonomous inspections
6. Standardize through visual workplace
management
7. Implement autonomous equipment management

13. © Operational Excellence Consulting. All rights reserved. 13
§ Preventive Maintenance
§ Corrective Maintenance
§ Maintenance Prevention
§ Breakdown Maintenance
§ Support for Autonomous
Maintenance
§ Specialized maintenance skills
§ Equipment repair skills
§ Inspection and measurement skills
§ Equipment diagnostic skills
§ Develop new maintenance
technologies
Planned Maintenance:
Main Activities
Improvement of Equipment
à MTBF
Improvement of Maintenance Skills
à MTTR
The dual focus of Planned Maintenance is improvement of equipment
(machine focus) and improvement of maintenance skills (people focus)
Planned Maintenance Approach

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Preventive maintenance which includes cleaning, checking,
lubrication and adjustment is health management for machines
Daily
prevention
Early
treatment
Prevent
Deterioration –
through daily maintenance
(cleaning, checking,
lubrication, adjustment)
Restore
Deterioration –
through preventive repairs
before problems occur
Health
checkups
Measure
Deterioration –
through routine
inspections and operating
checks
Preventive
medicine
Preventive
maintenance
Preventive Maintenance Approach

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The 6 Steps of Kaizen is a scientific method which can be used to
improve the OEE of an equipment through Kaizen events
Source: Kato & Smalley
1. Discover Improvement
Potential
3. Generate Original
Ideas
2. Analyze the Current
Methods
4. Develop an
Implementation Plan
5. Implement the Plan
6. Evaluate the New
Method
Kaizen
Six Steps of Kaizen

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The 5 Whys technique is applied by repeatedly asking the question
“Why?” which can drill down the symptoms and lead to the root
cause of a problem
5 Whys Technique
Why? Because…
1 Why won’t your car start? It ran out of gas.
2 Why did it run out of gas? I forgot to fill it up.
3 Why did you forget to fill it up? The fuel gage doesn’t work.
4 Why doesn’t the fuel gage work? I forgot to have it repaired.
5 Why did you forget to repair it?
I did not write it on the repair list when it
broke.
Root Cause

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The Visual Management Pyramid defines the types of “tools” that can
be applied to achieve the desired objectives
Visual Management Pyramid
Source: Practical TPM by James Leflar
Prevent
Abnormalities
Detect
Abnormalities
Warn about abnormalities
Build standards into the workplace
Share established standards
Share information and/or results of control activities
Sort, Set in order, Shine, Standardize & Sustain
Visual Display
5S
Visual Control
Poke-Yoke

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About
Operational Excellence
Consulting

19. © Operational Excellence Consulting. All rights reserved. 19
About Operational Excellence
Consulting
• Operational Excellence Consulting is a management
training and consulting firm that assists organizations in
improving business performance and effectiveness.
• The firm’s mission is to create business value for
organizations through innovative operational excellence
management training and consulting solutions.
• OEC takes a unique “beyond the tools” approach to enable
clients develop internal capabilities and cultural
transformation to achieve sustainable world-class excellence
and competitive advantage. For more information, please visit
www.oeconsulting.com.sg

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