Introduction to TPM – Objectives and

Benefits
September 29, 2008

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 Autonomous Maintenance

Maintenance Process Improvement

Systematic Equipment Improvement

TPM

Cross-Functional, Team-Based Improvement Activities Training & Skill Development

The Five Pillars of TPM

Early Equipment Management

 Textbook Definition

“TPM is a plant improvement methodology which

enables continuous and rapid improvement
through use of employee involvement, employee
empowerment, and closed-loop measurement of
results.”

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 TPM Implementation – Nakajima’s 12 Steps
1. Announce Top Management’s Decision to Introduce TPM
2. Launch Educational Campaign
3. Create Organizations to Promote TPM
4. Establish Basic TPM Policies and Goals
5. Formulate a Master Plan for TPM Development
6. Hold TPM “Kickoff”
7. Improve Equipment Effectiveness
8. Establish an Autonomous Maintenance Program for Operators
9. Set-up a Scheduled Maintenance Program for the Maintenance
Department
10. Conduct Training to Improve Operation and Maintenance Skills
11. Develop Initial Equipment Management Program
12. Implement TPM Fully and Aim for Higher Goals

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 Characteristics of TPM
ƒ Optimum relationships between people and
equipment/process
ƒ Involvement of everyone, from top leadership to
shopfloor workers
ƒ A cross-functional approach, involving all
departments
ƒ Implementation through small group teamwork
ƒ DATA DRIVEN!!!

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 Two Types of Teams

Manager Manager

Natural team Natural team

Cross-functional

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 Definition(s)
Note: The DREADED “M” word is not used!!!

So what does maintenance mean anyway…

Maintenance = The act of maintaining

Maintain = To keep in a state of order. To keep in
due (rightful, proper, fitting) condition, operation,
or force; keep unimpaired.
 Definition(s) cont…
Fix and Repair = Maintenance

HOZEN (Maintenance in Japanese) = Maintaining and

preserving perfection through Asset
Management.

TPM = Total Productive Management

TPM = Total Productive Manufacturing

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 TPM Goals
ƒ Zero accidents ƒ Zero unplanned
downtime
ƒ Minimum life cycle
cost ƒ Zero speed losses

ƒ Zero defects

Zero waste!

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 Results
ƒ Overall Equipment Effectiveness (OEE)
Improved

ƒ Mean Time Between Failure Improved

ƒ Mean Time To Repair Improved

ƒ Etc…

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 Actual “GREEN” Results
ƒ $60K/ Month Facilities Maintenance Savings

ƒ $700K Annual Savings “Other-than-hazardous-waste”

• TPM Process applied to facilities maintenance activities

¾ Plant Air System

¾ Plant Lighting during peak Kilowatt usage

¾ Plant Start-up/Shut-down Procedures

¾ Waste Water Treatment System

Note: Above results since 1998

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 TPM Is a Paradigm Shift

Old
Old Attitude
Attitude
“I“I operate,
operate, you
you fix”
fix”
“I“I fix,
fix, you
you design”
design” TPM
TPM Attitude
Attitude
“I“I design,
design, you
you “We
“Weareareall
allresponsible
responsible
for
forour
ourequipment,
equipment,
operate”
operate” our
ourplant,
plant,and
and
our
ourfuture”
future”

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 Training and Skill
Development

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Why Training and Skill Development

ƒ Operators and Maintenance:

• Should possess the training and skills
necessary to carry out all of the required TPM
activities so that they have…
¾ A clear understanding of the criteria for judging
normal and abnormal conditions
¾ Can be empowered to strictly enforce condition
management rules
¾ The ability to quickly respond to any and all
abnormalities

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 Early Equipment
Management (EEM) and
Maintenance Prevention
(MP) Design

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 EEM and MP Design
EEM and MP Design are two methods of making
improvements at the earliest possible stage, with the
goal of “fix and repair” and defect free equipment.

In other words…
Operator/Maintenance friendly equipment through
lessons learned on existing equipment and applied
to new equipment during the concept, design, and
installation phase(s).

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 EEM/MP Design Involvement
EEM/MP Design is a team approach. The team
should ALWAYS include members from…

ƒ Maintenance (hourly)
ƒ Production (hourly)
ƒ Engineering/Technical

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 Maintenance Process
Improvement (MPI)
(Planned, Scheduled Maintenance System)

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 MPI Tools and Activities
ƒ Well trained/skilled craftspeople
ƒ Lubrication Management
ƒ Preventive Maintenance system
ƒ Predictive Technologies
ƒ Documentation Management
ƒ EEM/MP Design Involvement
ƒ Maintenance Management System
ƒ Spare Parts Management

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 The Maintenance Techniques
ƒ Preventive Maintenance – preventing
breakdowns
ƒ Corrective Maintenance – improving or
modifying equipment to prevent breakdowns or
to make maintenance easier
ƒ Maintenance Prevention – designing and
installing equipment that needs little or no
maintenance
ƒ Breakdown Maintenance – repairing or fixing
after breakdowns occur

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 Systematic Equipment
Improvement
(Improve Equipment Effectiveness)

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 SEI
A systematic approach to eliminate waste
through analysis of the “6” major losses utilizing
cross-functional teams to continuously
investigate, test, and implement improvements
with a goal of maximizing equipment
effectiveness.

DATA DRIVEN PROCESS!!!

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 Six Major Losses to
Equipment Effectiveness

ƒ Failures ƒ Reduced speed

ƒ Setup/changeover ƒ Defects and rework
and adjustments
ƒ Startup loss
ƒ Idling and minor
stoppages

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 How the Losses Reduce Effectiveness

Overall
Perf.
Equipment = Availability x Efficiency x Quality
Effectiveness

Equipment Reduced Rejects and

Failures Speed Defects
Adjustments Minor Stops Startup
6 Major and Set-Ups and Idling Losses
Losses

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 Autonomous
Maintenance

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 What Is
Autonomous Maintenance?
ƒ A collaborative team activity involving
production, maintenance, and engineering
ƒ An approach that
• develops operating and maintenance skills
• strengthens communication and cooperation
ƒ A series of activities implemented in
well-defined developmental steps

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 Seven Steps of
Autonomous Maintenance
1. Conduct initial
cleaning/inspection
2. Eliminate sources of
contamination
3. Establish provisional
standards
4. Develop general
inspection training
5. Conduct general
inspections
6. Improve workplace
management and control
7. Participate in advanced
improvement activities

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Cross-Functional Team Activity

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 Zero Breakdown Strategies
ƒ Restore equipment
ƒ Maintain basic equipment conditions
ƒ Adhere to standard operating procedures
ƒ Improve operator maintenance skills
ƒ Don’t stop at emergency fixes
ƒ Correct design weaknesses
ƒ Study breakdowns relentlessly

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“Button-pushers” to Process
Owners

“Firefighters” to Maintainers

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