1. Meeting Agenda Cont.
I. TPM-8 Pillars-Laura Dietrich
II. Kick off TPM
I. Launching TPM- Preparatory Stage-Antoinette Lockett
II. Autonomous Maintenance- Xiaoyan Liu
III. Equipment Management Life Cycle- Xiaoyan Liu
IV. TPM Implementation-Waseem Manzoor
V. Launching TPM- Stabilization-Waseen Manzoor
VI. Eliminating Equipment Losses-Laura Dietrich
VII. Improvement Goals for Chronic Losses-Laura Dietrich
III. Overall Equipment Efficiency
I. What is OEE-Xiaoyan Liu
II. OEE Factors-Xiayon Liu
III. Calculating OEE-Waseem Manzoor
IV. TPM Benefits-Xiaoyan Liu
8. What is Total Productive Maintenance?
TPM is a plant improvement methodology which enables
continuous and rapid improvement of the manufacturing
process through use of employee involvement, employee
empowerment, and closed-loop measurement of results
9. Breakdown of TPM
TOTAL = All encompassing by maintenance and production individuals
working together
PRODUCTIVE = Production goods and services that meet or exceed
customers’ expectations
MAINTENANCE = Keeping equipment and plant in as good as or
better than the original conditions at all times
10. TPM - History
Productive maintenance (PM) originated in
the U.S. in late 1940’s & early 1950’s
Japanese companies modified and enhanced
it to fit the Japanese industrial environment
The first use the term TPM was in 1961 by
Nippondenso, a Japanese auto components
manufacturer
Seiichi Nakajima – head of JIPM, one of the
earliest proponents, known as the Father of
TPM
13. Goals of TPM
1. Aims at getting the most effective use of
equipment
2. Builds a comprehensive PM system
3. Brings together people from all departments
concerned with equipment
4. Requires the support and cooperation of
everyone from top managers down
5. Promotes and implements PM activities based
on autonomous small group activities.
6. Maintaining Equipment for life
7. Encouraging input from all employees
8. Using teams for continuous improvement
14. Three Principles of Prevention
Maintenance of normal conditions
Early discovery of abnormalities
Prompt response
18. Launching TPM- Preparatory Stage
Announce top management’s decision to introduce TPM
Launch an educational campaign to introduce TPM
Create an organizational structure to promote TPM
Establish basic policies
Form a master plan for implementing TPM
24. Launching TPM- TPM Implementation
Improve the effectiveness of each critical
piece of equipment
Set up and implement autonomous
maintenance
Establish a planned maintenance system in
the maintenance department
Provide training to improve operator and
maintenance skills
Develop an early equipment management
program
29. What is OEE
OEE (overall equipment efficiency) is a “best practices” way
to monitor and improve the efficiency of your
manufacturing processes
machines
manufacturing cells
assembly lines
31. World Class OEE
OEE Factor World Class
Availability 90.0%
Performance 95.0%
Quality 99.9 %
OEE 85.0%
32. Calculating OEE
Availability = Operating time/planned production
Performance = Ideal Cycle Time / Total Pieces or
(total pieces / Operating time)/Ideal Run time
Quality = Good Pieces / Total Pieces
OEE = Availability X Performance X Quality
33. Example OEE Calculation
Item Data
Shift length 8 hrs = 480 min.
Short Breaks 2@ 15 min. = 30 min
Meal Break 1 @ 30 min = 30 min
Down Time 47 min
Ideal Run Time 60 pieces per min
Total Pieces 19,271 pieces
Reject Pieces 423 pieces
39. TPM - Benefits
Improved equipment eliminates the root cause of
defects
Defects are prevented through planned maintenance
Preventive maintenance costs are reduced as
equipment operators conduct autonomous
maintenance
Improved equipment designs ensure that new
equipment naturally produces fewer defects
Simplified products designs and a redesigned process
produce with few defects
Engineers, technicians and managers are trained in
maintenance and quality
40. TPM - Benefits
(Japanese TPM Prize winners during 1982-1984)
Equipment failures reduced from 1,000/month
to 20/month
Quality defects reduced from 1.0% to 0.1%
Warranty claims reduced by 25%
Maintenance costs reduced by 30%
WIP decreased by 50%
Productivity improved by 50%. (Patterson &
Fredendall, 1995)