Third dimension tool of Lean Six Sigma

1. Total Productive
Maintenance
ISYE650 Class Presentation
Spring 2014
By Akhil Yelisetti

2. TPM overview
2
T P M
Total Productive
Maintenance
What’s TPM
How TPM
works
Concept Zero
TPM Targets
Why TPM
Objectives of
TPM

3. What’sT P M
• TPM wasdeveloped in the 1970's as amethodof involving
machineoperators in the preventive maintenanceof their
machines
– a reaction to increasing specialization and centralization of the maintenance
function that had createddivision-of-labor barriers between operators and the
maintenance of their machines and equipment.
– Also creating a sense of ownership in workers with Autonomous Maintenance
3

4. Objectives ofT P M
• Theoverriding objective of TPMis the elimination ofLOSSES.Losses, or
waste, includes equipment downtime, defects, scrap, accidents, wasted energy,
and labor inefficiency.
• TPM was introduced to achieve some of the following important objectives:
– Safer working environment, Job security
– Producing goods with improved quality and machinereliability
– Improved financial performance
– Producea low batch quantity at the earliest possible time.
– Goods send to the customers must benon defective
4

5. Why T P M
5
Before 1 Severe problem occured, there were 300 minor and 29 major problems to
handle.
Source: Kaizen Institute, Frankfurt
Heinrich‘s Law
TPM is a tool which addresses potential signs of machine break-downs and is therefore
an important instrument to prevent total machine crashes.
1
29
300
Severe problem
Minor problems
Major problems

6. Concept ZERO
• Thegoal ofTPMisto driveall wasteto zero: ZeroAccidents,Zero
Defects,ZeroBreakdowns.
• The Concept of Zero is built uponPoka-Yoke, in the design of the process to make
it impossible to makeand pass on defects.
• Poka-Yoke concepts are also commonlyapplied to equipment to prevent
breakdowns.
6

7. Performance Measure and 6 Losses
• OEE is the performance measureof TPM.
• Thus factors affecting OEE/ TPM:
• Availability
• Performance
• Quality
– Associated 6 big losses are:
• Availability Losses: Breakdown losses caused bythe equipment; Set-up
and adjustment losses
• Performance Losses: Minor stoppage losses; Speed losses
• Quality Losses: Quality defect and rework losses; Yield losses
7

8. Pillarsof TPM
8

9. How it Works
9

10. Types ofMaintenance
• BreakdownMaintenance:Thisoccurs when equipment failsbut doesnot affect
production or operationor extracostsother than repairs
• PreventiveMaintenance:A dailymaintenancedesignedto maintainequipment
againstfailingand alsoimprovedhealthcondition
– PeriodicMaintenance:Atimebasedmaintenance
– PredictiveMaintenance:Maintenancebased on condition monitoringby
employingsurveillancesystem
• CorrectiveMaintenance:Redesigningequipmentwith weaknessto improve
reliability
• MaintenancePrevention:Thisindicatesdesignof new machineby Cross
functional teams afterthorough study on weaknessof current machines
10

11. TPM Targets
11
P roduction:
Obtain Minimum80% OPE.
Obtain Minimum90% OEE( Overall Equipment Effectiveness )
Runthe machineseven duringlunch.( Lunchis for operators and not for machines!)
Quality:
Operate in a manner,so that thereareno customer complaints.
C osts:
Reduce themanufacturingcost by 30%.
D elivery:
Achieve100%success indelivering the goods as requiredby the customer.
Safety:
Maintain a accident freeenvironment.
M aintenance:
Develop Multi-skilled and flexible workers. AndCross functional teams

12. References
• http://www.plant-maintenance.com/articles/tpm_intro.shtml
• http://www.leanproduction.com/tpm.html
• http://technologyinterface.nmsu.edu/fall97/manufacturing/tpm2.html
• https://www.moresteam.com/lean/tpm.cfm
• http://www.epa.gov/lean/environment/methods/tpm.htm
• http://www.slideshare.net/exerciselean/tpm-presentation-
1522308?qid=647eedce-04f7-4ddf-9625-
6acfb0bc419d&v=default&b=&from_search=10
12

13. Queries
13