Total Productive maintenance (TPM)

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Laura Dietrich: Maintenance Manger
Antoinette Lockett: Plant Manger
Waseem Manzoor: Quality Manger
Xiaoyan Liu: Production Manger


Meeting Agenda
I.
II.

Understanding Downtime -Group
Major Losses of TPM -Antoinette Lockett
I.
II.
III.
IV.

III.

Planned Downtime Losses -Xiaoyan Liu
Unplanned Downtime Losses -Laura Dietrich
Reduce Speed LossesPoor Quality Losses -Waseem Manzoor

Total Productive Maintenance

I.
II.
III.
IV.
V.
VI.

What is TPM -Antoinette Lockett
Breakdown of TPM -Laura Dietrich
TPM History -Laura Dietrich
TPM Evolution
Goal of TPM -Antoinette Lockett
Three Principles of Prevention


Meeting Agenda Cont.
I.
II.

TPM-8 Pillars-Laura Dietrich
Kick off TPM

I.
Launching TPM- Preparatory Stage-Antoinette Lockett
II.
Autonomous Maintenance- Xiaoyan Liu
III. Equipment Management Life Cycle- Xiaoyan Liu
IV.
TPM Implementation-Waseem Manzoor
V.

Launching TPM- Stabilization-Waseen Manzoor
VI.
Eliminating Equipment Losses-Laura Dietrich
VII. Improvement Goals for Chronic Losses-Laura Dietrich
III.
Overall Equipment Efficiency

IV.

I.

What is OEE-Xiaoyan Liu

II.
III.

OEE Factors-Xiayon Liu
Calculating OEE-Waseem Manzoor

TPM Benefits-Xiaoyan Liu


Understanding
Downtime


MAJOR LOSSES


Planned Downtime losses

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Start-ups
shift changes
coffee and lunch breaks
planned maintenance shutdowns


Unplanned Downtime Losses

• Equipment breakdown
• Changeovers
• Lack of material


Reduced Speed Losses

• Idling and minor stoppages
• Slow-downs


Poor Quality Losses
• Process non-conformities
• Scrap


TPM

What is Total Productive
Maintenance?
• TPM is a plant improvement
methodology which enables continuous
and rapid improvement of the
manufacturing process through use of
employee involvement, employee
empowerment, and closed-loop
measurement of results


Breakdown of TPM
• TOTAL = All encompassing by
maintenance and production
individuals working together
• PRODUCTIVE = Production goods and
services that meet or exceed
customers’ expectations
• MAINTENANCE = Keeping equipment
and plant in as good as or better than
the original conditions at all times


TPM - History
• Productive maintenance (PM) originated in
the U.S. in late 1940’s & early 1950’s
• Japanese companies modified and enhanced
it to fit the Japanese industrial

environment
• The first use the term TPM was in 1961 by
Nippondenso, a Japanese auto components
manufacturer
• Seiichi Nakajima – head of JIPM, one of
the earliest proponents, known as the
Father of TPM


TPM - Evolution
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Breakdown maintenance
Preventive maintenance (PM)
Productive maintenance
Total productive maintenance



Goals of TPM
1. Aims at getting the most effective use of
equipment
2. Builds a comprehensive PM system
3. Brings together people from all departments
concerned with equipment
4. Requires the support and cooperation of
everyone from top managers down

5. Promotes and implements PM activities based
on autonomous small group activities.
6. Maintaining Equipment for life
7. Encouraging input from all employees
8. Using teams for continuous improvement


Three Principles of Prevention
• Maintenance of normal conditions
• Early discovery of abnormalities
• Prompt response


TPM 8 PILLARS


5s

Safety, health and
Environment

Office TPM

Training

Quality Maintenance

Planned Maintenance

Kobetsu Kaizen

Autonomous Maintenance

PILLARS OF TPM


Kick off TPM


Launching TPM- Preparatory Stage
• Announce top management’s decision
to introduce TPM
• Launch an educational campaign to
introduce TPM
• Create an organizational structure to
promote TPM
• Establish basic policies
• Form a master plan for implementing
TPM