3. Meeting Agenda
I. Understanding Downtime -Group
II. Major Losses of TPM -Antoinette Lockett
I. Planned Downtime Losses -Xiaoyan Liu
II. Unplanned Downtime Losses -Laura Dietrich
III. Reduce Speed Losses-
IV. Poor Quality Losses -Waseem Manzoor
III. Total Productive Maintenance
I. What is TPM -Antoinette Lockett
II. Breakdown of TPM -Laura Dietrich
III. TPM History -Laura Dietrich
IV. TPM Evolution
V. Goal of TPM -Antoinette Lockett
VI. Three Principles of Prevention
4. 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
12. 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
13. • 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
Breakdown of TPM
14. 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
17. 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
18. Three Principles of Prevention
• Maintenance of normal conditions
• Early discovery of abnormalities
• Prompt response
22. 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
28. • 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
Launching TPM- TPM Implementation
33. 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
35. World Class OEE
OEE Factor World Class
Availability 90.0%
Performance 95.0%
Quality 99.9 %
OEE 85.0%
36. 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
37. 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
43. 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
44. 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)
45. TPM – Success stories
• USPS Albany, New York: annual save of
$86,000; could save $4.5 million if applied
nationwide
• Yamato Kogyo Corp., Japan:
- productivity up by 130%,
- accidents cut by 90%,
- defects reduced by 95%,
- employee suggestion rate increased by
over 300%
