Introduction to lean manufacturing TPM1

Lorraine Fraser, P.Eng., M.Eng., MBA, CQE, CQA, CQM/OE, CSSBB
ASQ Toronto Section – November 11, 2015


 Introduction

To TPM
 Benefits of TPM
 What does TPM look like?
 How to implement TPM
 How to Sustain TPM
 Summary
 Questions

TPM


The 7 Wastes

TPM


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TPM stands for Total Productive Maintenance.
TPM Development was first published in Japan in 1982. Since then new
concepts and refinements have been added to the basic program.
TPM first took root in the automotive industry. More recently it has been
introduced in consumer goods, electronics, plastics and many others.
Administrative and support departments such as product development
and sales also use TPM.
Production output and rate, quality, safety, and the environment depend
almost entirely on the state of equipment.
TPM is a method for continuously improving the effectiveness of
production equipment and processes.

TPM


World Class Operating Excellence is Achieved using optimized work standards with
group activities of associates who demonstrate ownership

Office

People

Logistics

Early Equipment
Management

Training & Development

Productivity

Quality Management

Cost

Environment, Health &
Safety

Planned Maintenance

Quality

Autonomous Maintenance

Improvement

Focused

Safety

5S & Teams
TPM



 Guarantees Significant Tangible Results - Results achieved include –
reduction in equipment breakdowns, lower quality defects and claims,
higher productivity, shrinking inventory, lower number of accidents.

P… net productivity up by 2x
Q…process defect rate down 90%
C…production costs down 30%
D…production and work in process inventories halved
S…accidents 0
M…improvement suggestions up by 10x
 Transforms the Plant Environment – a rusty plant can be reborn as a
pleasant, safe working environment.
 Transforms the Employees - As concrete results are achieved, workers
become motivated. Associates begin to think of TPM as part of their
job.
TPM


Benefits of TPM

 Customers and visitors are impressed by these changes
 Confidence in the plant’s products increases.
 Overall Equipment Effectiveness (OEE) is maximized through
zero breakdowns and failures, zero accidents, zero defects
through total employee involvement.
 Equipment reliability and maintainability as contributors to
quality and productivity is increased.
 TPM culture promotes zero loss activities.
 TPM involves all associates from the shop floor to top
management.

TPM

Benefits of TPM

TPM



TPM


What Does TPM Look Like?

 Machine Operators are trained to do much of the maintenance
operations, and it’s part of their Standard Work

TPM


What Does TPM Look Like?

 Necessary tools are readily available

TPM


What Does TPM Look Like?

 Equipment is modified such that it easy to keep clean, easy
to see when maintenance is required.

Befor

e

After

TPM


What Does TPM Look Like?

 Happy and Engaged Associates……

TPM



How To Implement TPM?

1. Formally announce decision to introduce TPM.
2. Conduct TPM introductory education & publicity campaign
3. Create a TPM promotion organization.
Plant Manager

Companywide TPM promotion 
     Committee

Section Managers

     Plant TPM Promotion 
Committee 

Group Leaders

      Section TPM Promotion     
Committee

Shop Floor Associates

             PM circles

TPM


How To Implement TPM?

4. Establish basic TPM policy and goals.
Policy – example:
Establish a profitable corporate constitution, promote TPM

Establish numerical goals – examples:
Zero breakdowns,
Zero defects, seek to maximize overall equipment effectiveness.

TPM


How To Implement TPM?

5. Draft a master plan for implementing TPM.
To formulate a master plan for implementation decide what
activities must be pursued to achieve the TPM goals.

The core TPM activities are:
 Focused improvement
 Autonomous Maintenance
 Planned Maintenance
 Education and Training
 Early Equipment Management
 Quality Maintenance
 Administrative and support department activities (Logistics & Office)
6.Kick off TPM initiative – should be designed to cultivate an atmosphere
that raises morale and inspires dedication.
TPM


How To Implement TPM?

7. Build a corporate constitution designed to maximize production
effectiveness.
8. Build an early management system for new products and
equipment.
9. Build a quality maintenance system.
10. Build an effective administration and support system.
11. Develop a system for managing health, safety, and the
environment.
12. Sustain full TPM implementation and sustain levels.
The first pillars to implement are the Focused Improvement, Autonomous
Maintenance, Planned Maintenance, & Training and Development
Pillars
TPM

How To Implement TPM?

TPM


How To Implement TPM?

The Eight Major Plant Losses:
Shutdown loss
Production adjustment loss
Equipment failure loss
Process failure loss
Normal production loss
Abnormal production loss
Quality defect loss

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Loss deployment
◦ All pillars are responsible
for analyzing the loss
deployments for their
losses.
◦ As losses are reduced,
the priority of teams
selected will change

Reprocessing loss
TPM

How To Implement TPM?

TPM


How To Implement TPM?

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How To Implement TPM?

TPM