Total Productive Maintenance

Total Productive Maintenance
ENTC 380
The Need for TPM

• Think of productive equipment as we think of
our cars or telephones
– They are ready to go when we need them
– They need not run all the time to be productive
• For this concept to function properly
– The machines must be ready when we need them
– They must be shut down in such a fashion as to
be ready the next time
1
TPM in a Nutshell
• Critical adjunct to lean manufacturing
• Is Not breakdown maintenance
• Is deterioration prevention
• Proactive approach
– Aims to prevent any kind of slack before occurrence
“Zero error,
zero work-related accident, and
zero loss."
TPM Reasons
• To maintain quality
• To maintain production volume
• To maintain efficiency
• To protect investment in equipment
“If machine uptime is not predictable,

if process capability is not sustained,
we cannot keep up with sales.”
2
TPM Benefits
Typical improvements in a relatively short period
of time (6-12 months)
• Overall Equipment Effectiveness (capacity)

improvement of 25-65%
• Quality improvement of 25-50%
• Maintenance expenditure reductions of 10-50%
• Percent planned vs. unplanned maintenance
increase of 10-60%
TPM Goals
1. Improve equipment effectiveness
– Examine all losses which occur
2. Achieve autonomous maintenance
– Allow operators to take responsibility for
some of the maintenance tasks
3. Plan maintenance
– Systematically approach all maintenance
activities
4. Train all staff in relevant maintenance skills
– Ensure all staff have the necessary skills
5. Achieve early equipment management
– Move towards zero maintenance through
"maintenance prevention" (MP)
3
TPM Measurement
• Overall Equipment Effectiveness (OEE)
• Ties the 'six big losses'
– Equipment Downtime
– Engineering Adjustment
– Minor Stoppages
– Unplanned Breaks
– Time spent making reject product
– Waste
• To three measurables
– Availability (Time)
– Performance (Speed) and
– Yield (Quality)
TPM Measurement
From http://www.reliabilityweb.com/art05/tpm.htm
4
TPM Measurement
Overall Equipment Effectiveness
OEE = PA x PR x QR
• PA = Planned Availability
– PA = (avail. time – planned downtime)/avail. time
• PR = Performance Rate
– PR = (ideal cycle time x output)/operating time
• QR = Quality Rate
– QR = (output – rejects)/output
OEE Example
One press in a plant for one week of operation
• Operating schedule = 120 hrs/week
• Planned downtime = 250 min/week
• Maintenance downtime = 500 min/week
• Changeover time = 4140 min/week
• Total output = 15,906 pieces
• Ideal production rate = 9.2 pieces/min
• Rejected pieces = 558 for the week
5
OEE Example
OEE = PA x PR x QR
PA = (available time – planned downtime)/available time
available time = (120 hrs)(60 min/hr) = 7200 min
planned downtime = 250 minutes
PA = [(7200 – 250) – (500 + 4140)]/7200 = 0.33
PR = (ideal cycle time x output)/operating time
operating time = available time – total downtime
= 7200 – (250 + 500 + 4140) = 2,310 min
PR = (1/9.2 pieces/min)(15,906)/(2,310 min)
= (0.109)(15,906)/2,310 = 0.75
QR = (output – rejects)/output = (15,906 – 558)/15,906
= 0.96
OEE = PA x PR x QR = (0.33)(0.75)(0.96) = 0.24 = 24%
OEE Analysis
• Is this good? (OEE = 24%)
• No, not at all!
• How can we improve the OEE?
• Let’s consider world-class improvements
in uptime, quality and production that
– Reduce downtime losses to 695 min/week
– Reduce number of rejects to 545/week
– Increase production to 54,516 pieces/week
6
OEE Example w/ Improvements
OEE = PA x PR x QR
PA = (available time – planned downtime)/available time
available time = (120 hrs)(60 min/hr) = 7200 min
planned downtime = 250 minutes
PA = [(7200 – 250) – 695]/(7200 – 250) = 0.90
PR = (ideal cycle time x output)/operating time
operating time = available time – total downtime
= 7200 – (250 + 695) = 6,255 min
PR = (1/9.2 pieces/min)(54,516)/(6,255 min)
= (0.109)(54,516)/6,255 = 0.95
QR = (output – rejects)/output = (54,516 – 545)/ 54,516
= 0.99
OEE = PA x PR x QR = (0.90)(0.95)(0.99) = 0.85 = 85%
TPM Measurement
Simplified OEE
Good Output Produced

• OEE1 = -----------------------------------------------
Required Production Time x Ideal Rate
or
Actual output
• OEE2 = ------------------------------------
Theoretical maximum output
7
OEE Example
Simplified OEE
OEE1 = Good Output Produced/(Req. Prod. Time)(Ideal Rate)

OEE1-old = 15,348/(2310)(9.2) = 0.72 = 72%
OEE1-new = 53,971/(6255)(9.2) = 0.94 = 94%
or
OEE2 = Actual output/Theoretical maximum output
OEE2-old = 72%
OEE2-new = 94%
Types of Maintenance
• Breakdown maintenance
– Waits until equipment fails and repair it
• Preventive maintenance
– Regular maintenance (cleaning, inspection, oiling and re-
tightening)
– Retains the healthy condition of equipment and prevents failure
– Periodic maintenance (time based maintenance - TBM)
– Predictive maintenance (condition based maintenance)
• Corrective maintenance
– Improves equipment and its components so that preventive
maintenance can be carried out reliably
• Maintenance prevention
– Improves the design of new equipment
8
TPM Implementation
• Operators know what maintenance
tasks are theirs and what tasks are
appropriate for the skilled maintenance
crew
• Ownership of the manufacturing
process is encouraged among all
employees
• Teamwork is necessary for success
TPM Implementation
• TPM starts with 5S
• Problems cannot be clearly seen when
the work place is unorganized
• Cleaning and organizing the workplace
helps the team to uncover problems
• Making problems visible is the first step
of improvement
9
TPM Implementation
5S
Japanese English Equivalent 'S'
Term Translation term
Seiri Organization Sort
Seiton Tidiness Systematize
Seiso Cleaning Sweep
Seiketsu Standardization Standardize
Shitsuke Discipline Self-Discipline
TPM Strategies
From http://www.mamtc.com/lean/building_tpm.asp
10
References
• Plant Maintenance Resource Center
– http://www.plant-maintenance.com/articles/tpm_intro.shtml
• Wikipedia
– http://en.wikipedia.org/wiki/Total_Productive_Maintenance
• Tool and Manufacturing Engineers Handbook
– Volume 7, Chapter 15
• Maintenance 2000 Limited
– http://www.maint2k.com/what-is-tpm.html
• NIST
– http://www.mep.nist.gov/totalproduc/totalproduc.htm
• Reliability Web.com
– http://www.reliabilityweb.com/art05/tpm.htm
• MAMTC – The Manufacturing Edge
– http://www.mamtc.com/lean/building_tpm.asp
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Total Productive Maintenance

The Need for TPM

“If machine uptime is not predictable,

• Overall Equipment Effectiveness (capacity)

Good Output Produced

OEE1 = Good Output Produced/(Req. Prod. Time)(Ideal Rate)

Seiton Tidiness Systematize

Seiso Cleaning Sweep

Seiketsu Standardization Standardize

Shitsuke Discipline Self-Discipline

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