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Partners for Creative Solutions, Inc.
36 Deerfield Rd, Shrewsbury, MA 01545
508 845-1546 tmcbride@pcs-info.com
Total Productive Maintenance

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TPM Training Agenda
 TPM – History, benefits and typical results
 Definition and “5 Pillars” of TPM
 The “6 Big Losses”
 Autonomous Maintenance
 Maintenance Prevention
 Setting Standards & Sustaining the Benefits
 TPM and Safety
 The Advisory Team
 Equipment Improvement Teams (EIT’s)
 TPM vs. 5S
 Summary of TPM topics

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Origins of TPM
 Breakdown maintenance (RTF) - historical
 Preventive Maintenance concept – introduced in1951
 Productive Maintenance introduced later
 Included
 Preventive maintenance
 Improvement-related maintenance
 Maintenance prevention
 Still primarily maintenance department
 Never achieved zero breakdowns or defects

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Origins of TPM
 Total Productive Maintenance
 Brought operators into the picture
 Small group activities
 Teamwork between operators and maintenance
 Involvement & support throughout the company

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No Tolerance for Breakdowns
 Equipment breakdowns impact
 Customer service
 Production costs
 Maintenance costs
 Effectiveness of “manufacturing cells” or “flow
lines”
 Breakdowns result in “chaos”

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The Last 50 Years
 In the 1950’s, about 70% of durable goods sold in
the world were made in the U.S. …today << 10%
 In the 1950’s, there were over 25 U.S. television
manufacturers …by the early 1990’s, only 1
(Zenith) …today??
 In the 1950’s, the largest growing job was in
manufacturing…not the case today!!
Most manufacturing industries are fighting a war
to survive!

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Benefits of TPM to the Company
 Improved plant productivity and capacity
 Lower operating costs
 Improved equipment lifespan
 Better ability to satisfy customers
Bottom Line: TPM increases
long-term viability

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Benefits of TPM for Operators &
Maintenance Personnel
 Increased skills through additional training
 Better job satisfaction
 Operators – More involvement in solving annoying
equipment problems
 Maintenance – More challenging work
 Better job security

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Typical TPM Results
 Overall equipment effectiveness up 25-65%
 Quality defects down 25-50%
 Maintenance expenditures down 10-50%
 Percent planned vs. unplanned maintenance
increased 10-60%

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Definition
TPM is a company-wide system developed to
maintain, monitor, and improve all capital assets
of a company. For production it is a system that
maximizes equipment effectiveness and
maintains product flow.
 TPM is not just about “maintenance”. It is about
getting the most overall benefit from your equipment
over the life of the equipment.
 TPM will not be an overnight success. Implementing it
throughout a plant correctly will take several years.

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Shift in Attitudes
Operator Maintenance Operator Maintenance
Conventional TPM
I use I maintain &
I fix
We maintain

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5 Pillars of TPM
1. Improvement activities designed to increase
equipment effectiveness (OEE)
2. Autonomous maintenance program performed
by equipment operators
3. A planned maintenance system
4. Training to improve operation & maintenance
skills
5. Effective new equipment design and startup

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TPM Emphasizes Prevention
Three Principles of Prevention
1. Maintain normal conditions
2. Early discovery of abnormalities
a) Operator
b) Maintenance
3. Prompt response

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The Six Big Equipment Losses
1. Breakdowns
2. Setups and adjustment
3. Idling and minor stoppages
4. Speed
5. Quality defects and rework
6. Start-up (loss of yield)

15. Overall equipment effectiveness = Availability x Performance rate x Quality rate
(OEE)
Breakdown
Setup and adjustment
Others Idling & minor stoppages
Reduced speed
Quality defects & rework
Start-up yield

16. Operation time (Scheduled time available – Downtime)
Availability = ______________________________________________ x 100
Scheduled time available
processed amount x ideal cycle time
Performance rate = _____________________________
Operation time
Quality rate = Amount good / amount produced

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Improving OEE
1. Measure the extent of the 6 big losses
2. Analyze the causes (but focus your efforts )
3. Develop solutions & create an improvement plan
4. Set targets and estimate the benefits to OEE
5. Carry out the plan
6. Establish measurements to monitor results
7. Repeat as necessary

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Eliminating Breakdowns
Workplace Conditions Contribute to Losses
 Filthy equipment
 Oil and lubricant leaks
 Moving parts encrusted with raw materials or debris
 Disorderly wiring, hoses, etc.
 Equipment mechanisms hidden or difficult to access
 Workplace disorder
 A belief that conditions cannot improve

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Eliminating Breakdowns
Why machines fail
 Disregard for basic needs (housekeeping, lube..)
 Incorrect operating conditions
 Lack of skill or knowledge of operator
 Machine deterioration
 Routine
 Accelerated
 Design deficiency

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Eliminating Breakdowns
 Two kinds of breakdowns
 Function loss (function completely lost) - Sporadic
 Function reduction (works, but with loss of speed or
quality) - Chronic
 Two kinds of breakdown maintenance
 Planned (pre-emptive)
 Unplanned (firefighting)

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Autonomous Maintenance
The principal way production workers participate in
TPM
Purpose
1. Brings production & maintenance people together to
slow routine deterioration and halt accelerated
deterioration
2. Helps operators learn more about their equipment
(the cause and effect)
3. Prepares operators to be active partners with
maintenance and engineering in improving equipment
performance and reliability

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Steps to Implementing Autonomous
Maintenance
Step 1: Initial cleaning and inspection
Step 2: Eliminate sources of contamination and
inaccessible areas
Step 3: Develop and test cleaning, inspection,
and lubrication standards
Step 4: General inspection training and
inspection procedures
Step 5: Conduct autonomous general
inspections

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Steps to Implementing Autonomous
Maintenance
Step 6: Organize and manage the workplace
Step 7: Ongoing autonomous maintenance and
continued improvement

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An advanced Improvement method
 Maintenance Prevention
Design-stage activities aimed at making new equipment
reliable, easy to care for, and user friendly

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Sustaining TPM
 Audits
 Visual activity boards
 Team charter
 Team activities, goal, schedule, and progress
 Cleaning, inspection, and lubrication standards
 Workplace organization standards
 Trend charts for each of the big 6 losses
 Inspection reports
 Audit results
 Before and after photos

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TPM and Safety
 Safety is the cornerstone of
production activities
 Accidents usually occur when unsafe
behavior is combined with
unsafe conditions
 For every major accident there are
29 minor accidents and 300 near misses
 Safety should always be the #1 priority

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Setting Up a TPM Structure
EIT
EIT
EIT
EIT
EIT
EIT
TPM
Advisory
Team
Mgmt

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Advisory Team - Responsibilities
 Guide & champion TPM implementation
 Assess current equipment OEE and develop a
process for measuring the “6 big” losses
 Develop a TPM master plan
 Set plant-wide standards for TPM implementation
 Monitor and evaluate progress
 Serve on EIT’s

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Equipment Improvement Teams -
Responsibilities
 Return equipment to near new condition
 Investigate and reduce the “big 6” equipment
losses
 Transfer routine maintenance skills to operators
 Set standards for routine maintenance and
inspections by operators
 Organize the work area for more
effective/efficient maintenance

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Setting Goals for Your TPM Program
 Short term – 12 months
 Establish an autonomous maintenance program for “x”
machines
 Increase OEE by “y”% within for individual work
centers
 Long term – Reach a plant OEE of 85% within 3
years (world class is considered about 85%)

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Comparing TPM to 5S
 5S emphasizes
 Productivity of workers
 Organizing and visual indicators
 TPM emphasizes
 Effectiveness of equipment
 Partnership between maintenance & production
 Reducing lifetime equipment costs
 Both emphasize
 Initial cleaning and repair
 Safety

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Shift in Equipment Maintenance
Activities
Breakdown
PM
Planned repair
FROM
THIS
to
Autonomous
PM
Predictive
Planned repair
Breakdown
THIS

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Review of TPM’s benefits
 For the company
 Higher Overall Equipment Effectiveness
 Less “firefighting” to repair machines
 Lower operating costs
 Better able to meet commitments to customers
 Improved ability to compete in the world marketplace

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Review of TPM’s benefits
 For employees
 Less pressure on maintenance for urgent repairs
 Less pressure on production to recover from
breakdown losses
 Better cooperation between maintenance, production,
and other departments
 Reduced chance of accidents
 Higher job satisfaction
 Improved job security