Post on 29-Mar-2015
transcript
Total Productive Maintenance
TPM
AGENDA
TPM
Agenda
» Introduction To TPM» Why – Benefits?» Typical Maintenance Strategies» What Does TPM Look Like?» How to Start Using TPM» Sustaining» Summary / Questions
AGENDA
TPM
INTRODUCTION
TPM
What is TPM?
» TPM is a method for continuously improving the effectiveness of production equipment and processes
Introduction
TPM
» By improving On Demand availability of the equipment, through improved maintenance
How is this Accomplished?
How is this Different from Other Maintenance Programs?
» Primary difference between TPM and most maintenance programs is the involvement of the machine operator as a front line defense against…
Introduction
TPM
– Equipment breakdowns and other unplanned downtime
– Scrap and rework caused by poor equipment performance
– Reduced productivity due to running at reduced speeds, idling, or stoppages requiring operator attention
– Equipment startup losses
Brief History of TPM
» Preventative maintenance originated in the United States in 1940’s
Introduction
TPM
» Japanese auto manufacturers studied these methods in the 1950’s
» First true TPM initiative developed by Nippondenso in the late 1960’s
» First true TPM in the United States developed by Kodak’s Tennessee Eastman facility in 1987
Why is TPM Important?
TPM
Why is TPM Important
TPM
Why is TPM Important
TPM
WHY???
» Maximizes the productivity of equipment for its entire life cycle
Why is TPM Important – Benefits
TPM
» Extends equipment life
» Increases the amount of time equipment can be doing what we need it to do
» Builds / Trains a workforce that can most effectively help the organization best utilize it’s equipment
WHY??? To reduce Waste?
» Equipment Breakdowns
Why is TPM Important – Benefits
TPM
» Setup and Adjustment Delays
» Idling and minor stoppages
» Reduced Speed
» Process Defects
» Reduced Yield
Typical Maintenance Strategies
TPM
Types
Typical Maintenance Strategies
TPM
» Reactive» Preventive» Predictive» Corrective Maintenance» Maintenance Elimination
» All of these can have a place, yet some better than others
Most Common Strategy?
Typical Maintenance Strategies
TPM
“If it ain’t broke, don’t fix it”.
» Reactive Maintenance
Reactive Maintenance = 55%
Typical Maintenance Strategies
TPM
» Advantages• Low cost• Less staff
» Disadvantages• Increased cost due to unplanned
downtime of equipment • Increased labor cost, especially if
overtime is needed ,cost involved with repair or replacement of equipment.
• Possible secondary equipment or process damage from equipment failure.
• Inefficient use of staff resources.
Can we get better?
Typical Maintenance Strategies
TPM
» Preventive Maintenance
Time or Machine cycle based maintenance functions
Preventive Maintenance = 31%
Typical Maintenance Strategies
TPM
» Developed by US Navy» Advantages• Cost effective in many capital-intensive processes• Flexibility allows for the adjustment of maintenance schedules• Increased component life cycle• Energy savings• Reduced equipment or process failure• Estimated 12% to 18% cost savings over reactive maintenance
program.
» Disadvantages • • Catastrophic failures still likely to occur• Labor intensive• Includes performance of unneeded maintenance• Potential for incidental damage to components in conducting unneeded
maintenance.
Anything Better?
Typical Maintenance Strategies
TPM
» Predictive Maintenance
Maintenance functions based on feedback, predicting that something needs to be done.
Predictive Maintenance = 12%
Typical Maintenance Strategies
TPM
» Advantages• Increased component operational life/availability.• Allows for preemptive corrective actions.• Decrease in equipment or process downtime.• Decrease in costs for parts and labor.• Better product quality.• Improved worker and environmental safety.• Improved worker morale.• Energy savings.• Estimated 8% to 12% cost savings over preventive
maintenance program.
» Disadvantages• Increased investment in diagnostic equipment.• Increased investment in staff training.• Savings potential not readily seen by management.
More?
Typical Maintenance Strategies
TPM
» Corrective Maintenance
Modifying a piece of equipment such that it will last longer.
More?
Typical Maintenance Strategies
TPM
» Maintenance Elimination
Removing or reducing the need for maintenance to occur
What Does TPM Look Like?
TPM
TPM Implemented?
What Does TPM Look Like?
TPM
» Machine Operators are trained to do much of the maintenance operations, and it’s part of their Standard Work
TPM Implemented?
What Does TPM Look Like?
TPM
» Tools necessary are readily available
TPM Implemented?
What Does TPM Look Like?
TPM
» Equipment modified such that easy to keep clean, easy to see when maintenance is required.
Before
After
TPM Implemented?
What Does TPM Look Like?
TPM
» More examples of easily cleaned and seen
Before
After
Filtered Air
TPM Implemented?
What Does TPM Look Like?
TPM
» More examples of easily cleaned and seen
Before
After
TPM Implemented?
What Does TPM Look Like?
TPM
» Equipment modified such that easy to maintain
How to Implement?
TPM
How To….
How To Implement?
TPM
1. Select Equipment to work on
2. Begin with 5Sing, Initial Clean Up
3. Define Machine Operator Maintenance Tasks• Modify equipment to facilitate tasks
4. Define Maintenance Technician Tasks• Provide “informative” tools to assist
5. Sustain
How To….
How To Implement? | Equipment Selection
TPM
1. Select Equipment to work on….• Equipment that is giving you problems with…
• Unplanned downtime• Excessive quality problems• Excessive repair costs• Premature “end of life” failures• Running slower than “design” to prevent
breakdowns
How To….
How To Implement? | Equipment Selection
TPM
2. 5S Event….• Improves ability to perform regular inspections• Allows the discovery of potential problems• Log problems and potential problems and develop
an immediate action plan• Mark all lubrication, fluid connections and
directions, etc• Paint equipment
How To….
How To Implement? | Equipment Selection
TPM
3. Defining Machine Operator Tasks• Develop Standards and Checklists
• Cleaning• Lubrication• Visual Checks• Procedures to keep equipment “as new”
How To….
How To Implement? | Equipment Selection
TPM
3. Make Machine Operator maintenance tasks easier/quicker• Easy to see when things need to be
maintained• Lubrication needs become obvious to operator• Routine cleaning operations easier• Machine disassembly minimized• Automate maintenance when possible• Clear signals when maintenance is needed
How To….
How To Implement? | Equipment Selection
TPM
3. Defining Machine Operator Tasks (cont.)• Train Operators on….
• Visual checks• Hydraulics• Electrical / electronics• Mechanical drive systems• Complex lubrication• Safety• Procedures for minor repair and
replacement• Criteria delineating operator and technician
approved activities
How To….
How To Implement? | Equipment Selection
TPM
3. Defining Machine Operator Tasks (cont.)• Implement Daily Operator Activities
• Review checklists with operators• Ensure operator training is complete• Finalize checklist schedules
How To….
How To Implement? | Equipment Selection
TPM
4. Define Maintenance Tech Tasks (Reactive) • Provide Tech support to operator questions• Provide clear communication path• Spare Parts Program
• Equip Manufacturer recommendations• Breakdown History Data• Kanban
How To….
How To Implement? | Equipment Selection
TPM
4. Define Maintenance Tech Tasks (Preventive) • Eliminate Equipment Deterioration
• Scheduled general inspections• Equipment overhauls• Triggered by checklists
• Identify and Resolve Chronic Problems• Breakdown history log• Root cause analysis methods• 5 Why analysis
How To….
How To Implement? | Equipment Selection
TPM
4. Define Maintenance Tech Tasks (Predictive) • Develop and Analyze Equipment History
• Plot failure history• Correlate with Equipment Quality
Performance• Determine Equipment Parameters That Predict
Failure• Use information from equipment
manufacturer• Oil, vibration, temperature analysis
• Develop Equipment Monitoring Systems• Ensure appropriate accuracy and tolerance• Lease equipment to ensure usability before
purchase
Sustain
TPM
Sustaining….
Sustain
TPM
» Measuring progress / status is key to sustaining
» Primary Measurement tool is OEE
» OEE – Overall Equipment Effectiveness, is measured….
OEE = Equip Availability X Performance Efficiency X Quality Rate
» Audit machine operator’s standard work» Audit maint tech’s standard work
Summary
TPM
» TPM is a method for continuously improving the effectiveness of production equipment and processes
Summary
TPM
» By improving On Demand availability of the equipment, through improved maintenance
» With a primary focus on involving machine operators in routine maintenance
» And making that maintenance easily seen, easily done, and effective
Q&A
TPM