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Total Productive Maintenance

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Total Productive Maintenance TPM * * * * * * * * * * * * * * * * * * How To . How To Implement? | Equipment Selection TPM 3. Defining Machine Operator Tasks Develop ... – PowerPoint PPT presentation

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Title: Total Productive Maintenance


1
Total Productive Maintenance
TPM
2
AGENDA
TPM
3
Agenda
AGENDA
  • Introduction To TPM
  • Why Benefits?
  • Typical Maintenance Strategies
  • What Does TPM Look Like?
  • How to Start Using TPM
  • Sustaining
  • Summary / Questions

TPM
4
INTRODUCTION
TPM
5
What is TPM?
Introduction
  • TPM is a method for continuously improving the
    effectiveness of production equipment and
    processes

How is this Accomplished?
  • By improving On Demand availability of the
    equipment, through improved maintenance

TPM
6
How is this Different from Other Maintenance
Programs?
Introduction
  • Primary difference between TPM and most
    maintenance programs is the involvement of the
    machine operator as a front line defense against
  • Equipment breakdowns and other unplanned downtime
  • Scrap and rework caused by poor equipment
    performance
  • Reduced productivity due to running at reduced
    speeds, idling, or stoppages requiring operator
    attention
  • Equipment startup losses

TPM
7
Brief History of TPM
Introduction
  • Preventative maintenance originated in the United
    States in 1940s
  • Japanese auto manufacturers studied these methods
    in the 1950s
  • First true TPM initiative developed by
    Nippondenso in the late 1960s
  • First true TPM in the United States developed by
    Kodaks Tennessee Eastman facility in 1987

TPM
8
Why is TPM Important?
TPM
9
Why is TPM Important
TPM
10
Why is TPM Important
TPM
11
WHY???
Why is TPM Important Benefits
  • Maximizes the productivity of equipment for its
    entire life cycle
  • Extends equipment life
  • Increases the amount of time equipment can be
    doing what we need it to do
  • Builds / Trains a workforce that can most
    effectively help the organization best utilize
    its equipment

TPM
12
WHY??? To reduce Waste?
Why is TPM Important Benefits
  • Equipment Breakdowns
  • Setup and Adjustment Delays
  • Idling and minor stoppages
  • Reduced Speed
  • Process Defects
  • Reduced Yield

TPM
13
Typical Maintenance Strategies
TPM
14
Types
Typical Maintenance Strategies
  • Reactive
  • Preventive
  • Predictive
  • Corrective Maintenance
  • Maintenance Elimination
  • All of these can have a place, yet some better
    than others

TPM
15
Most Common Strategy?
Typical Maintenance Strategies
  • If it aint broke, dont fix it.
  • Reactive Maintenance

TPM
16
Reactive Maintenance 55
Typical Maintenance Strategies
  • Advantages
  • Low cost
  • Less staff
  • Disadvantages
  • Increased cost due to unplanned downtime of
    equipment
  • Increased labor cost, especially if overtime is
    needed ,cost involved with repair or replacement
    of equipment.
  • Possible secondary equipment or process damage
    from equipment failure.
  • Inefficient use of staff resources.

TPM
17
Can we get better?
Typical Maintenance Strategies
  • Time or Machine cycle based maintenance functions
  • Preventive Maintenance

TPM
18
Preventive Maintenance 31
Typical Maintenance Strategies
  • Developed by US Navy
  • Advantages
  • Cost effective in many capital-intensive
    processes
  • Flexibility allows for the adjustment of
    maintenance schedules
  • Increased component life cycle
  • Energy savings
  • Reduced equipment or process failure
  • Estimated 12 to 18 cost savings over reactive
    maintenance program.
  • Disadvantages
  • Catastrophic failures still likely to occur
  • Labor intensive
  • Includes performance of unneeded maintenance
  • Potential for incidental damage to components in
    conducting unneeded maintenance.

TPM
19
Anything Better?
Typical Maintenance Strategies
  • Maintenance functions based on feedback,
    predicting that something needs to be done.
  • Predictive Maintenance

TPM
20
Predictive Maintenance 12
Typical Maintenance Strategies
  • Advantages
  • Increased component operational
    life/availability.
  • Allows for preemptive corrective actions.
  • Decrease in equipment or process downtime.
  • Decrease in costs for parts and labor.
  • Better product quality.
  • Improved worker and environmental safety.
  • Improved worker morale.
  • Energy savings.
  • Estimated 8 to 12 cost savings over preventive
    maintenance program.
  • Disadvantages
  • Increased investment in diagnostic equipment.
  • Increased investment in staff training.
  • Savings potential not readily seen by management.

TPM
21
More?
Typical Maintenance Strategies
  • Modifying a piece of equipment such that it will
    last longer.
  • Corrective Maintenance

TPM
22
More?
Typical Maintenance Strategies
  • Removing or reducing the need for maintenance to
    occur
  • Maintenance Elimination

TPM
23
What Does TPM Look Like?
TPM
24
TPM Implemented?
What Does TPM Look Like?
  • Machine Operators are trained to do much of the
    maintenance operations, and its part of their
    Standard Work

TPM
25
TPM Implemented?
What Does TPM Look Like?
  • Tools necessary are readily available

TPM
26
TPM Implemented?
What Does TPM Look Like?
  • Equipment modified such that easy to keep clean,
    easy to see when maintenance is required.

Before
After
TPM
27
TPM Implemented?
What Does TPM Look Like?
  • More examples of easily cleaned and seen

Filtered Air
Before
After
TPM
28
TPM Implemented?
What Does TPM Look Like?
  • More examples of easily cleaned and seen

After
Before
TPM
29
TPM Implemented?
What Does TPM Look Like?
  • Equipment modified such that easy to maintain

TPM
30
How to Implement?
TPM
31
How To.
How To Implement?
1. Select Equipment to work on
2. Begin with 5Sing, Initial Clean Up
  • 3. Define Machine Operator Maintenance Tasks
  • Modify equipment to facilitate tasks
  • 4. Define Maintenance Technician Tasks
  • Provide informative tools to assist

5. Sustain
TPM
32
How To.
How To Implement? Equipment Selection
  • 1. Select Equipment to work on.
  • Equipment that is giving you problems with
  • Unplanned downtime
  • Excessive quality problems
  • Excessive repair costs
  • Premature end of life failures
  • Running slower than design to prevent breakdowns

TPM
33
How To.
How To Implement? Equipment Selection
  • 2. 5S Event.
  • Improves ability to perform regular inspections
  • Allows the discovery of potential problems
  • Log problems and potential problems and develop
    an immediate action plan
  • Mark all lubrication, fluid connections and
    directions, etc
  • Paint equipment

TPM
34
How To.
How To Implement? Equipment Selection
3. Defining Machine Operator Tasks
  • Develop Standards and Checklists
  • Cleaning
  • Lubrication
  • Visual Checks
  • Procedures to keep equipment as new

TPM
35
How To.
How To Implement? Equipment Selection
3. Make Machine Operator maintenance tasks
easier/quicker
  • Easy to see when things need to be maintained
  • Lubrication needs become obvious to operator
  • Routine cleaning operations easier
  • Machine disassembly minimized
  • Automate maintenance when possible
  • Clear signals when maintenance is needed

TPM
36
How To.
How To Implement? Equipment Selection
3. Defining Machine Operator Tasks (cont.)
  • Train Operators on.
  • Visual checks
  • Hydraulics
  • Electrical / electronics
  • Mechanical drive systems
  • Complex lubrication
  • Safety
  • Procedures for minor repair and replacement
  • Criteria delineating operator and technician
    approved activities

TPM
37
How To.
How To Implement? Equipment Selection
3. Defining Machine Operator Tasks (cont.)
  • Implement Daily Operator Activities
  • Review checklists with operators
  • Ensure operator training is complete
  • Finalize checklist schedules

TPM
38
How To.
How To Implement? Equipment Selection
4. Define Maintenance Tech Tasks (Reactive)
  • Provide Tech support to operator questions
  • Provide clear communication path
  • Spare Parts Program
  • Equip Manufacturer recommendations
  • Breakdown History Data
  • Kanban

TPM
39
How To.
How To Implement? Equipment Selection
4. Define Maintenance Tech Tasks (Preventive)
  • Eliminate Equipment Deterioration
  • Scheduled general inspections
  • Equipment overhauls
  • Triggered by checklists
  • Identify and Resolve Chronic Problems
  • Breakdown history log
  • Root cause analysis methods
  • 5 Why analysis

TPM
40
How To.
How To Implement? Equipment Selection
4. Define Maintenance Tech Tasks (Predictive)
  • Develop and Analyze Equipment History
  • Plot failure history
  • Correlate with Equipment Quality Performance
  • Determine Equipment Parameters That Predict
    Failure
  • Use information from equipment manufacturer
  • Oil, vibration, temperature analysis
  • Develop Equipment Monitoring Systems
  • Ensure appropriate accuracy and tolerance
  • Lease equipment to ensure usability before
    purchase

TPM
41
Sustain
TPM
42
Sustaining.
Sustain
  • Measuring progress / status is key to sustaining
  • Primary Measurement tool is OEE
  • OEE Overall Equipment Effectiveness, is
    measured.

OEE Equip Availability X Performance Efficiency
X Quality Rate
  • Audit machine operators standard work
  • Audit maint techs standard work

TPM
43
Summary
TPM
44
Summary
  • TPM is a method for continuously improving the
    effectiveness of production equipment and
    processes
  • By improving On Demand availability of the
    equipment, through improved maintenance
  • With a primary focus on involving machine
    operators in routine maintenance
  • And making that maintenance easily seen, easily
    done, and effective

TPM
45
QA
TPM
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