Total Productive Maintenance (TPM)

1© Operational Excellence Consulting. All rights reserved.
Total Productive
Maintenance
(TPM)
Total Productive
Maintenance
(TPM)
© Operational Excellence Consulting. All rights reserved.

Program Outline
1. Overview of TPM
2. TPM Foundations: 5S & Visual Management
3. TPM Tools
4. Equipment Loss & OEE
5. 8 Pillars of TPM
6. Key Pillars of TPM
- Autonomous Maintenance
- Planned Maintenance
- Focused Improvement
- Education & Training
7. Other TPM Pillars
8. TPM Implementation
9. Critical Success Factors
This document is a partial preview. Full document download can be found on Flevy:
http://flevy.com/browse/document/total-productive-maintenance-tpm-158

Productive Maintenance (“Profitable PM”)
Productive
Maintenance
(“Profitable PM”)
Preventive
Maintenance
Breakdown
Maintenance
Corrective
Maintenance
Maintenance
Prevention
Preventing breakdowns
Designing and installing
equipment that needs little or no
maintenance
Improving or modifying equipment
to prevent breakdowns or to make
maintenance easier
Repairing after breakdowns occur

Maintenance Prevention
• Designing or specifying equipment that doesn’t break
down and easy to maintain
• Studying of maintenance data and developing
“maintenance-free” designs for equipment that doesn’t
breakdown, safe and easy to use
• For MP to succeed, operators and maintenance people
need to collect data

Machine Failures Have Many Hidden Causes
Less
Visible
Visible
Failure
Loosening
Contamination
CorrosionLeaks
FlawsDeformation
VibrationCracks
BacklashImproper Temperature
Wear
Failure is what we
see but is only the
tip of the iceberg
Failure is what we
see but is only the
tip of the iceberg
Minor machine
defects are
generally
unnoticed but
are the cause of
almost all
machine failures
Minor machine
defects are
generally
unnoticed but
are the cause of
almost all
machine failures

TPM is a Paradigm Shift
Maintenance Operator Maintenance
Old Attitude TPM Attitude
I use I maintain &
I fix
We maintain
Operator

Why TPM?
• Avoid wastage in a quickly
changing economic environment
• Producing goods without
reducing product quality
• Produce a low batch quantity at
the earliest possible time
• Reduce cost
• Goods delivered to customers
must be non-defective

TPM Pillars & Activities 1
Pillar Activities
Focused equipment and
process improvement
Measure of equipment- or process-related losses
and specific improvement activities to reduce the
losses
Autonomous maintenance Operator involvement in regular cleaning,
inspection, lubrication, and learning about
equipment to maintain basic conditions and spot
signs of trouble
Planned maintenance A combination of preventive, predictive, and
proactive maintenance to avoid losses, and
planned responses to fix breakdowns quickly
Quality maintenance Activities to manage product quality by
maintaining optimal operating conditions

How TPM Benefited Kodak
• Increased uptime, fewer breakdowns and longer-lasting parts
• Significant reduction in unit manufacturing cost
• Reduction in Maintenance overtime by 10%
• Maintenance costs dropped to below budget allocation
• Employee absenteeism fell from 3% to less than 2% within 2 years
• Significant improvement in maintenance customer satisfaction
• Reduction in spare parts inventory
• Reduction in MTTR
• Reduction in backlog
• Two-third reduction in the annual cost of cutting blades
Source: TPM – Collected Practices & Cases, Productivity Press, 2005

Meaning of 5S
Principles General Description
1S Sort Remove what is not needed and keep
what is needed
2S Set in Order Arrange essential items in order for
easy access
3S Shine Keep things clean and tidy; no trash
or dirt in the workplace
4S Standardize Establish standards and guidelines to
maintain a clean workplace
5S Sustain Make 5S a habit and teach others to
adhere to established standards

1S : Sort
• The first step in 5S is to get
rid of what we do not need
• Go through all the tools,
equipment, materials, etc.
in the plant and work areas
Keep only essential items
Everything else is stored
away or discardedThis document is a partial preview. Full document download can be found on Flevy:

2S : Set In Order - Examples

3S : Shine – Practice Tips 1
• Obtain appropriate tools and supplies
for cleaning
• Increase the lighting in the work area
• Divide the area into zones
• Define responsibilities for cleaning
• Repair any leaks on equipment
• Provide protection for the persons
doing the cleaning
• Clean machines, floors, walls and
ceilings

4S : Standardize – Practice Tips 1
• Define work instructions and procedures
• Make standards to detect abnormality
• Implement poka-yoke (error proofing) systems
• Train employees to follow established standards and
guidelines
Cleaning, inspection and lubrication
• Train new employees on the 5S system. Develop
training documentation for this purpose.This document is a partial preview. Full document download can be found on Flevy:

How to Sustain 5S?
• Get management commitment
• Get everyone involved
• Get authorization from management for 5S activities
• Promote 5S in the organization
• Do it all the way
• Gemba walk by CEO
• Conduct monthly review by 5S committee
• Use 5S as a platform to launch other continuous
improvement programs/initiatives

Visual Controls
• The name given to a whole
range of activities for
communicating and controlling
what needs to be done
• 5S can be enhanced by the use
of visual controls
• Use visual controls to help you
monitor results and look for
things easily and quickly
Note: Visual management IS
NOT decoration
Note: Visual management IS
NOT decoration

Warning Sensors
• Warning sensors signal the operator that there is a
problem. These sensors use colors, alarms, lights to get
the workers attention!
• These sensors may be used in conjunction with a
contact or energy sensor to get the operators attention.
Color Code
Lights
Lights connected to Micro switches
& timers

Session 3:
Key Tools for TPM

Fuguai Tagging (F-Tag)
• Fuguai Tags are attached to
equipment where problems are
discovered
• Two categories of Fuguai Tags:
Blue Tag – repairs can be made by
operator
Red Tag – repairs by maintenance
staff
• Fuguai Register
A log for all Fuguai’s issued and
resolved

What is One-Point Lesson?
• One-point lesson is a 5-10 min self-study lesson drawn
up by team members
• Lesson covers a single aspect of equipment or machine
structure, functioning or inspection method
• Is a highly effective tool because it is short and focused
on a topic

Example: One-Point Lesson
Source: DIYLean.com

Board is filled by hand. Checklists (beside board) are also made manually.
Example: 5S Activity Board

Overall Equipment Effectiveness (OEE) 2
Overall Equipment Effectiveness = Availability x Performance x Quality
Availability = Operating Time / Planned Production Time
Performance = (Ideal Cycle Time x Total Pieces) / Operating Time
Quality = Good Pieces / Total Pieces
Simplest OEE Formula:
OEE = (Good Pieces x Ideal Cycle Time) / Planned Production Time
Where:
• Good Pieces (pieces that are manufactured without any defects)
• Ideal Cycle Time (the theoretical fastest possible time to manufacture one piece)
• Planned Production Time (the total time that the production asset is scheduled for production)
• Fully Productive Time (producing only good pieces, as fast as possible, with no down time)

Eight Major Pillars of TPM
The eight pillars of TPM are mostly focused on proactive and
preventative techniques for improving equipment reliability.
TPMintheOffice
Safety&Environmental
Management
AutonomousMaintenance
PlannedMaintenance
FocusedImprovement
EarlyEquipment
Management
QualityMaintenance
Education&Training
5S & Visual Management
TPM Goals:
Zero Defects, Zero Breakdowns,
Zero Accidents

Autonomous Maintenance
• Benefits:
Gives operators greater “ownership” of their
equipment
Increases operators’ knowledge of their equipment
Ensures equipment is well-cleaned and lubricated
Identifies emergent issues before they become
failures
Frees maintenance personnel for higher-level tasks
Objective: To place responsibility for routine maintenance, such as
cleaning, lubricating, and inspection, in the hands of operators

Natural & Forced Deterioration
• Deterioration is what leads equipment to break down or
generate defective parts
• Natural Deterioration – Normal wear caused by parts
rubbing against one another
• Forced Deterioration – Deterioration that happens
sooner than it would naturally. Usually caused by our
failure to do something we ought to. Examples:
Not keeping parts clean and lubricated
Ignoring excessive loads in moving partsThis document is a partial preview. Full document download can be found on Flevy:

Example 2: Autonomous Maintenance
Source: Nippon Denso
Color-coded lubrication container station
ensures the right lubricant is applied to
the right equipment

7 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 continuous improvement activities

Planned Maintenance
• Benefits
Significantly reduces instances of unplanned down
time
Enables most maintenance to be planned for times
when equipment is not scheduled for production
Reduces inventory through better control of wear-
prone and failure-prone parts
Objective: To increase equipment reliability and minimize maintenance
cost by reducing breakdowns and developing efficient maintenance
methods

Planned Maintenance
• How to achieve the natural life cycle of individual
machine elements
Correct operation
Correct set-up
Cleaning
Lubrication
Retightening
Feedback and repair of
minor defects
Quality spare partsThis document is a partial preview. Full document download can be found on Flevy:

Identifying a Complete Machine
Preventive Maintenance Plan
• A complete scheduled maintenance plan consists of
seven elements:
1. PM checklist
2. PM schedules
3. Inspection specifications
4. Replacement part numbers
5. PM procedures
6. Part logs
7. Quality checks

Planned Maintenance – Practice Tips 2
• Do not use equipment failure to schedule maintenance
work. This is breakdown – not preventive –
maintenance.
• Attempt to develop a maintenance plan for each
component. Redesign machine only if an acceptable
maintenance plan cannot be developed.

Session 7:
Focused Improvement

Focused Improvement
• Benefits
Recurring problems are identified and resolved by
cross-functional teams
Combines the collective talents of a company to
create an engine for continuous improvement
Objective: To achieve regular, incremental improvements in equipment
operation by small groups of employees working together proactively so
as to continually improve OEE performance

Focused Improvement – Factors
Affecting Product Quality
Product defect is affected by the 4Ms:
• Machines: equipment function and precision
• Men (people): level of human skills, behaviors and
adherence to standards
• Materials: quality of incoming parts or materials
• Methods: appropriateness of operating and inspection
methods and standardsThis document is a partial preview. Full document download can be found on Flevy:

Kaizen Toolbox for TPM Problem Solving
• Where - Where
analysis
• Why - Why analysis
• Fishbone diagram
• 5W1H
• Pareto chart
• Flow charts
• Check Sheet
• Graph/Control chart
• Histogram
• Scatter Diagram
• Brainstorming

No/Low Cost Solution: One-Motion Methods
Cam Method
Quick Changeover
Wing Nut Method
Pear-Shaped Hole Method
Tighten
Here
Attach and
Remove
Here

Quality Maintenance
• Quality rate has a direct correlation with:
Material conditions
Equipment precision
Production methods
Process parameters

Quality Maintenance – Basic Principles
1. Set standards for distinguishing normal and abnormal
states
2. Strictly follow all the standards and rules that have
decided on
3. Discover any abnormalities in the equipment that may
cause defects
4. Immediately begin the proper treatment for any
abnormalitiesThis document is a partial preview. Full document download can be found on Flevy:

Perspectives of Equipment Weak Points
• The search for weak points in equipment can be carried
out from the following perspectives:
Facilitating Autonomous Maintenance
Increasing Ease of Operation
Improving Quality
Improving Maintainability
Safety

Education and Training
• Benefits
Operators develop skills to routinely maintain
equipment and identify emerging problems
Maintenance personnel learn techniques for proactive
and preventative maintenance
Managers are trained on TPM principles as well as on
employee coaching and development
Objective: To enhance employees’ skills in TPM methodology and fill in
knowledge gaps necessary to achieve TPM goals

Education and Training
• The different phases of skills are:
Phase 1 : Do not know
Phase 2 : Know the theory but cannot do
Phase 3 : Can do but cannot teach
Phase 4 : Can do and also teach

TPM in the Office
• Office TPM should be started after activating four other
pillars of TPM (AM, FI, PM, T&E)
• Office TPM must be followed to improve productivity,
efficiency in the administrative functions and identify and
eliminate losses
• This includes analyzing processes and procedures
towards increased office automation

Focused Improvement Topics for Office
TPM
• Inventory reduction
• Lead time reduction of critical processes
• Motion and space losses
• Retrieval time reduction
• Equalizing the work load
• Improving the office efficiency by eliminating the time
loss on retrieval of information, by achieving zero
breakdown of office equipment like telephone and fax
lines

Safety & Environmental Management
• Focus is to create a safe workplace and a surrounding
area that is not damaged by our process or procedures
• This pillar will play an active role in each of the other
pillars on a regular basis
• To create awareness among employees various
competitions like safety slogans, quiz, posters, etc.
related to safety can be organized at regular intervals
• Alignment to ISO 14001 and ISO 18001 standardsThis document is a partial preview. Full document download can be found on Flevy:

Session 9:
TPM Implementation

Roles of Pillar Champion
• Roles
To Lead and Facilitate the TPM Activities for their Pillar
Accountable for Pillar results and progress
Train and Schedule TPM Steps
Form Pillar Committee
Present progress to Steering Committee
Activity Board – using PDCA cycle
• Membership and Frequency
Weekly
Core Members – Pillar Champions,
Committee members
Review results
Plan Next Steps

TPM Implementation:
2. Introductory Education Campaign
• Training for different target
audiences
Awareness vs. intensive
• Seminars for managers
• “TPM 101” briefings - Slide
presentations for all employees
• Visit sites/organizations with
good TPM practices

TPM Implementation:
5. Preparation and Formulation of a Master
Plan
• A master plan lays out your goals,
what you will do to achieve them
and when you will achieve them
• Detailed plans for each pillar have
to be prepared
• Managed as one program

TPM Implementation:
7. Develop an Equipment Management
Program (2)
• Typical membership of a team
Five to seven operators
A maintenance person
A technical expert
• Tools
Pareto chart
Cause & effect
Root cause
Methods analysis

TPM Implementation:
10. Increase Skills of Production and
Maintenance Personnel
• The training sessions must be
planned shortly after the kick-off
presentation
• 2 major components
Soft skills training
Technical training
• Train leaders together
• Have leaders share information
with group members

TPM Implementation:
12. Perfect TPM Implementation and Raise TPM Levels
• Evaluate for the PM Award: The
Japanese Institute for Productive
Maintenance (JIPM) runs the
annual PM Excellence Award.
They provide a checklist for
companies applying for the
award.
• Set higher goals
• Annual TPM site competition
• President’s TPM Award
TPM Pillar Award

How to Sustain TPM
• Engaging employees
• Aim for early success
• Providing active leadership
• Share success stories
• Rewards and recognition
• Continuously improve OEE
• Evolving the TPM initiative over
timeThis document is a partial preview. Full document download can be found on Flevy:

Copyrights of all the pictures used in this presentation are held by their respective owners.

1
Flevy (www.flevy.com) is the marketplace
for premium documents. These
documents can range from Business
Frameworks to Financial Models to
PowerPoint Templates.
Flevy was founded under the principle that
companies waste a lot of time and money
recreating the same foundational business
documents. Our vision is for Flevy to
become a comprehensive knowledge base
of business documents. All organizations,
from startups to large enterprises, can use
Flevy— whether it's to jumpstart projects, to
find reference or comparison materials, or
just to learn.
Contact Us
Please contact us with any questions you may have
about our company.
• General Inquiries
support@flevy.com
• Media/PR
press@flevy.com
• Billing
billing@flevy.com

Total Productive Maintenance (TPM)

Recommended

Recommended

More Related Content

More from Flevy.com Best Practices

More from Flevy.com Best Practices (20)

Recently uploaded

Recently uploaded (20)

Total Productive Maintenance (TPM)