TPM total productive maintenance

TPM
Total Productive Maintenance


TPM - definition

•

TPM can be defined as a systematic work
method aiming to develop disturbance
free processes at lowest possible cost
through the commitment of all co-workers
(LCP-Consultants)


TPM – Total Productive Maintenance
•

Total Effectiveness

•

Total Preventive Maintenance

•

Total Commitment


Why TPM?
•

Replace routine with development

•

Increased commitment from all co-workers

•

Continuous improvements

•

Foreseeable operations

•

Improved safety and environment


TPM Structure
Evaluation and new goals

Preparation

Develop a master plan

Planned maintenance
Education and training

Safety, hygiene and environment

Policy and goals

Autonomous maintenance

Effective administration

Organisation and pilot

Continuous improvements
Kick-off

Education

Quality maintenance

Effectiveness

Management’s decision

Early equipment management

Implementation


TPM Structure
Evaluation and new goals

Preparation

Develop a master plan

Planned maintenance
Education and training

Safety, hygiene and environment

Policy and goals

Autonomous maintenance

Effective administration

Organisation and pilot

Continuous improvements
Kick-off

Education

Quality maintenance

Effectiveness

Management’s decision

Early equipment management

Implementation

TPM Structure
Evaluation and new goals

Preparation

Develop a master plan

Planned maintenance
Education and training

Safety, hygiene and environment

Policy and goals

Autonomous maintenance

Effective administration

Organisation and pilot

Continuous improvements
Kick-off

Education

Quality maintenance

Effectiveness

Management’s decision

Early equipment management

Implementation


TPM Structure
Evaluation and new goals

Preparation

Develop a master plan

Planned maintenance
Education and training

Safety, hygiene and environment

Policy and goals

Autonomous maintenance

Effective administration

Organisation and pilot

Continuous improvements
Kick-off

Education

Quality maintenance

Effectiveness

Management’s decision

Early equipment management

Implementation


The six big losses
•
•
•
•
•
•

Failures and break-downs
Set-up and adjustments
Idling and minor stoppages
Reduced speed
Defects and rework
Start-up losses

Sporadic and chronic losses
Loss

Sporadic fault

Chronic faults

Optimal condition

Time


Sporadic and chronic losses
$
Chronic loss, cycle time
40s instead of 36s = 25 days
Sporadic fault
30 hrs.

weeks


OEE calculations
Planning factor =

Available time
Planning related
stopps

Speed loss

Available
operative time

Value
adding
operative
time

Defects

Net
operative
time

Unplanned
stopps

Planned
production time

Failures and
breakdowns
Set-up and
adjustments
Idling and
minor stoppage

Available time – Planning related stop time

Available time
Availability =
Planned prod. time – Unplanned stop time
Planned prod. time

Performance rate =
Bought CT x items produced

Reduced speed
Defects and
rework

Available operative time

Quality rate =

Start-up losses

Items produced - Defects
Items produced

Overall Equipment Effectiveness (OEE)
= (Planning factor) x= Availability x Performance rate x Quality rate


OEE meassures
T A K K B w6 18

100%
90%

80%
70%
97, 8%

60%

99, 6%

79, 7%
50%
80, 3%

77, 6%

40%
30%
20%
10%
0%
Pl aner i ngsf aktor

Ti l l gängl i ghet

Anl äggni ngsutnyttj ande

Kval i tet

TAK

Group activities

Autonomous maintenance group
Cross functional improvement group

Target oriented cross functional group


Quality improvement tools
7QC/QM

Identify, prioritize and analyze failures

FMEA

Identify and evaluate potential weaknesses

FTA

Identify causes of failures and their logic connections

PM-analysis

Reduce all chronic loss to zero


Example: ABB
TAK KB

2,1%

1,2%

0,7%

0,5%

0,2%

100%
13,3%

90%
27,9%

10,0%

7,1%
Kvalitetsförluster

24,3%

7,3%

15,0%
Hastighetsförluster

11,0%

80%

Stillestånd

70%

60%

10,1%

Effektivitet

15,1%

50%
82,2%

40%

30%

75,0%

77,7%

64,3%
55,0%

20%

10%

0%

Januari

Februari

Mars

April

Maj


TPM Structure
Evaluation and new goals

Preparation

Develop a master plan

Planned maintenance
Education and training

Safety, hygiene and environment

Policy and goals

Autonomous maintenance

Effective administration

Organisation and pilot

Continuous improvements
Kick-off

Education

Quality maintenance

Effectiveness

Management’s decision

Early equipment management

Implementation


Autonomous maintenance


Autonomous maintenance
•

Teach the operators to react on cause instead of result

•

By increased kompetence and understanding the operators may:
–
–
–
–

Eliminate minor stoppages
Prevent break-downs
Secure implemented improvements
Improve quality, safety, and environment

•

In the long run operators start to perform maintenance tasks

•

Daliy inspections replaces repair and low frequent controls

•

Implemented through seven well-defined steps

•

Takes long time to implement, often years


The seven-step ladder

Description
Factory focusing step.
From maintenance to
control.
Focuses the operators.
They learn advanced
inspection and
maintenance techniques
Equipment
focusing step.
Secures the basic
condition of the
equipment

Competence
Repair skills

7. Autonomous maintenance

Understands the
relation between
maintenance and
product quality

6. Organize the work environment

5. Autonomous inspection
4. General inspection training

3. Standards for cleaning and lubrication

2. Counter meassures at the problem source

1. Basic cleaning and order

Understands the
functions and structure
of the machines
Can find defects and
understand the principles for
improvements of the
equipment


TPM Structure
Evaluation and new goals

Preparation

Develop a master plan

Planned maintenance
Education and training

Safety, hygiene and environment

Policy and goals

Autonomous maintenance

Effective administration

Organisation and pilot

Continuous improvements
Kick-off

Education

Quality maintenance

Effectiveness

Management’s decision

Early equipment management

Implementation


Planned maintenance
Condition Based Maintenance

Improvement Maintenance

Restoring Maintenance

Preventive Maintenance

Corrective Maintenance

Maintenance planning
Maintenance control
Spare part control
Economy control

Implementation of planned maintenance leads to:
-Increased MTBF and MTBM
-Decreased MTTR, MWT and M
-Closer to 0-faults, 0-stops and 0-accidents

Information feedback

Activities for improved
maintenance effectiveness

Activities for improved OEE


TPM Structure
Evaluation and new goals

Preparation

Develop a master plan

Planned maintenance
Education and training

Safety, hygiene and environment

Policy and goals

Autonomous maintenance

Effective administration

Organisation and pilot

Continuous improvements
Kick-off

Education

Quality maintenance

Effectiveness

Management’s decision

Early equipment management

Implementation


TPM Structure
Evaluation and new goals

Preparation

Develop a master plan

Planned maintenance
Education and training

Safety, hygiene and environment

Policy and goals

Autonomous maintenance

Effective administration

Organisation and pilot

Continuous improvements
Kick-off

Education

Quality maintenance

Effectiveness

Management’s decision

Early equipment management

Implementation

Early equipment management
Goal and
requirements

The process has to goals:
•To reach stable, full speed production at start-up.
•To, as far as possible, meet the detailed
requirements for the equipment.

Basic properties

LCC

Acquisition process
Project

Structure and process thinking

Experience development
MP-design

Early detection of
problems

The included activities are aiming for new equipment to be:
•Reliable and producing non defective products.
•Easy to mend and set up, and fast to start after set-up changes.
•Easy to maintain, and fast to localize faults and repair.
•Easy to clean, lubricate and inspect.
•Resource efficient and safe.