LM Unit2 Module 5

Lean manufacturing
Unit2 Module 5
Dr.P.Senthilkumar
Associate Professor/mechanical
Contents
1. TPM
2. Pillars of TPM
3. OEE
4. Implementation of TPM.
Total productive maintenance
• A system of maintaining and improving the integrity

of production, safety and quality systems through
the machines, equipment, processes, and
employees that add business value to an
organization.
Pillars of TPM
5S Foundation
• Goal of 5S is to create a work environment that is
clean and well-organized
• Consists of five elements
Sort (eliminate anything that is not truly needed in the

work area)
Set in Order (organize the remaining items)
Shine (clean and inspect the work area)
Standardize (create standards for performing the
above three activities)
Sustain (ensure the standards are regularly applied)
Autonomous Maintenance
• Places responsibility for routine maintenance, such
as cleaning, lubricating, and inspection, in the hands
of operators.
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.
Planned Maintenance
• Schedules maintenance tasks based on predicted
and/or measured failure rates.
Significantly reduces instances of unplanned stop 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.
Quality Maintenance
• Design error detection and prevention into
production processes. Apply Root Cause Analysis
to eliminate recurring sources of quality defects.
Specifically targets quality issues with
improvement projects focused on removing root
sources of defects.
Reduces number of defects.
Reduces cost by catching defects early (it is
expensive and unreliable to find defects through
inspection).
Focused Improvement
• Have small groups of employees work together
proactively to achieve regular, incremental
improvements in equipment operation.
Recurring problems are identified and resolved by

cross-functional teams.
Combines the collective talents of a company to

create an engine for continuous improvement.
Early Equipment Management
• Directs practical knowledge and understanding of
manufacturing equipment gained through TPM towards
improving the design of new equipment.
New equipment reaches planned performance levels

much faster due to fewer startup issues.
Maintenance is simpler and more robust due to practical

review and employee involvement prior to installation.
Training and Education
• Fill in knowledge gaps necessary to achieve TPM
goals. Applies to operators, maintenance personnel and
managers.
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.
Safety, Health, Environment
• Maintain a safe and healthy working

environment.
Eliminates potential health and safety risks,

resulting in a safer workplace.
Specifically targets the goal of an accident-free

workplace.
TPM in Administration
• Apply TPM techniques to administrative
functions.
Extends TPM benefits beyond the plant floor by

addressing waste in administrative functions.
Supports production through improved
administrative operations (e.g. order processing,
procurement, and scheduling).
OEE ( Overall Equipment Efficiency )
• OEE = A x PE x Q
• A - Availability of the machine. Availability is proportion of time machine is actually available

out of time it should be available.
• A = ( MTBF - MTTR ) / MTBF.
• MTBF - Mean Time Between Failures = ( Total Running Time ) / Number of Failures.
• MTTR - Mean Time To Repair.
• PE - Performance Efficiency. It is given by RE X SE.
• Rate efficiency (RE) : Actual average cycle time is slower than design cycle time because of
jams, etc. Output is reduced because of jams
• Speed efficiency (SE) : Actual cycle time is slower than design cycle time machine output is
reduced because it is running at reduced speed.
• Q - Refers to quality rate. Which is percentage of good parts out of total produced sometimes
called "yield".
TPM Implementation

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Lean manufacturing

• A system of maintaining and improving the integrity

Sort (eliminate anything that is not truly needed in the

Significantly reduces instances of unplanned stop time.

Recurring problems are identified and resolved by

Combines the collective talents of a company to

New equipment reaches planned performance levels

Maintenance is simpler and more robust due to practical

• Maintain a safe and healthy working

Eliminates potential health and safety risks,

Specifically targets the goal of an accident-free

Extends TPM benefits beyond the plant floor by

• A - Availability of the machine. Availability is proportion of time machine is actually available

• A = ( MTBF - MTTR ) / MTBF.

• PE - Performance Efficiency. It is given by RE X SE.

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