introduction to total productive maintenance (tpm)

INTRODUCTION TO

TOTAL PRODUCTIVE MAINTENANCE (TPM)

What is TPM

Total Productive Maintenance (TPM) is a well-defined and time-tested concept for maintaining plants and equipment TPM can be considered as the medical science of machines

TPM was introduced to achieve the following objectives

1048707 Avoid waste in a quickly changing economic environment1048707 Produce goods without reducing product quality1048707 Reduce costs1048707 Produce a low batch quantity at the earliest possible time1048707 Send only non-defective parts to the customers

TPM involves all Denso Associates The major difference between TPM and other concepts is that the Production Operators are directly involved in the process of maintaining their equipment

The old notion of I operate the equipment You Maintain it is NOT followed

History with TPMTotal Productive Maintenance is an innovative Japanese concept the origin of which can be traced back to the early 1950s when preventive maintenance was introduced in Japan

The concept of preventive maintenance originated in the USA Preventive maintenance is the concept of daily maintenance designed to maintain equipment in good condition and prevent failure through the prevention of deterioration and periodic inspections Nippondenso was the first company to introduce plant-wide preventive maintenance in 1960

Nippondenso operators used machines to produce products and the maintenance group maintained the machines however with the introduction of more and more factory automation maintenance became a problem because more maintenance personnel were required

Management decided that the production operators could perform the routine maintenance on their equipment (Autonomous Maintenance one of the features of TPM) The maintenance group could then focus on essential maintenance projects

Thus Nippondenso which already practiced preventive maintenance also added Autonomous Maintenance performed by production operators The maintenance group began identifying modifications to improve overall equipment reliability The modifications were made or incorporated in new equipment This led to Maintenance Prevention

Preventive maintenance along with Maintenance PreventionAutonomous Maintenance and Maintainability Improvement gave birth to Productive Maintenance The goal of productive maintenance was to maximize plant and equipment effectiveness to achieve optimum life cycle cost of production equipment

By then Nippondenso had made quality circles involving the employeesrsquo participation in implementing Productive Maintenance Based on these developments Nippondenso was awarded by the Japanese Institute of Plant Engineers (JIPE) the distinguished plant prize for developing and implementing TPM

Nippondenso of the Toyota group became the first company to obtain the TPM certification

Denso Vision 2015To meet our Goals we must surpass customer expectations of quality cost and deliverywhich create a new level of value for everyone

TPM Goals and BenefitsThe goal of the TPM program is to markedly increase production while at the same time increase associate morale and job satisfaction TPM brings maintenance into focus as a necessary and vitally important part of the business It is no longer regarded as a non-profit activity Downtime for maintenance is scheduled as a part of the manufacturing day and in some cases as an integral part of the manufacturing process The goal is to hold emergency and unscheduled maintenance to a minimum

The benefits of TPM are

bull A Safer Workplacebull Associate Empowermentbull An Easier Workloadbull Increased Productionbull Fewer Defectsbull Fewer Breakdownsbull Fewer Short Stoppages (Chokotei)bull Decreased Costsbull Decreased Waste (Muda)

Equipment EfficiencyEquipment that does not operate well or is always breaking down causes more work for everyone and can cause customer dissatisfaction If equipment breaks down during production many other processes can be affected Refer to the figure

Production equipment not being able to produce products with normal equipment performance is due to 6 major losses

bull Startup Lossbull SetupAdjustment Lossbull Cycle Time Lossbull Chokotei Lossbull Breakdown Lossbull Defect Loss

If the equipment operates without breakdowns and is consistently working well everyonersquos work is easier the company is more profitable and working conditions are improved

The inverted stair step diagram on the following page shows graphically how the losses in availability performance and quality work together to reduce the overall effectiveness of a machine

The top bar total operating time shows the total time a machine is available to make a product This is usually considered to be 480 minutes per 8-hour shift

Bars A and B show availabilityBar A represents the net operating time which is the time available for production after subtracting planned downtime (no scheduled production) such as a holiday no orders or no personnel

Bar B shows the actual running time after subtracting downtime losses such as equipment failures and setup and adjustments

Bars C and D show performanceBar C represents the Target Output of the machine during the running time calculated at the designed speed of the machine Below it bar D represents the actual output reflecting speed losses such as minor stoppages and reduced operating speed

Bars E and F show quality As you can see the actual output (E) is reduced by defect losses such as scrap and startup losses shown as the shaded portion of bar F As this diagram shows the bottom-line good output is only a fraction of what it could be if losses in availability performance and quality were reduced

The diagram also suggests that to maximize effectivenessmdashto grow the good output on the bottom linemdashyou must reduce not only quality losses but also availability and performance losses The three factors work together and the lowest percentage is usually the constraint that most needs addressing

MaintenanceMaintenance is defined as ldquoactivities that retain machine performancerdquoThe number frequency and severity of equipment breakdowns can be decreased with proper maintenance Maintenance includes servicing current conditions and taking action to prevent future problemsTypes of MaintenanceThe major categories of Maintenance includebull Breakdown Maintenancebull Preventive Maintenancebull Predictive Maintenancebull Corrective Maintenancebull Maintenance Prevention

Breakdown Maintenance (BM) is when we wait for equipment to fail and then repair it Forexample some electronic equipment is simply replaced when it failsEquipment breakdown is classified according to the duration of the stop Refer to the diagram

Preventive Maintenance is periodic maintenance that retains the condition of equipment and prevents failure through the prevention of deterioration periodic inspection and equipment condition diagnosis PM includes daily cleaning inspection lubrication and tightening

Autonomous Maintenance is daily preventive maintenance (cleaning inspection lubrication and re-tightening) performed by the equipment operator

Preventive Maintenance is further divided into Periodic Maintenance and PredictiveMaintenance Periodic Maintenance is time-based which involves periodically inspecting servicing and cleaning equipment and replacing parts to prevent problems Predictive Maintenance is condition-based which involves predicting the service life of important parts based upon inspection or diagnosis to use the parts to the limit of their service life

Corrective Maintenance improves equipment and its components so that preventive maintenance can be performed reliably Equipment with a design weakness is redesigned with corrective maintenance to improve reliability or maintainability

Maintenance Prevention deals with improving the design of new equipment Current machine data (information leading to failure prevention easier maintenance prevention of defects safetyand ease of manufacturing) are studied and designs are incorporated in new equipment

Pillars of TPM

Pillars of TPM

5S

5S ndash The Foundation of TPMTPM starts with 5S Problems cannot be clearly seen when the work place is unorganized Cleaning and organizing the workplace helps the team to uncover problems Making problems visible is the first step of improvement

SupervisorSupervisor

EARLY MANAGEMENT amp MAINTENANCE PREVENTION

TPM is a Lean tool for Quality and Productivity

TPM IMPLEMENTATION

TPM as a Lean Initiativebull Competitive costs require

ndash Spending controlndash Defect control ndash Downtime reduction

bull TPM = Total Productive Maintenancendash Proactive (with all employees involved)ndash Preventivendash Predictivendash Planned

Why Changebull ACTIONS

ndash Reduce defectives scrapndash Reduction of lost production timendash Lowest possible cost by reducing waste

Lean System

5S Visual Factory

T P MStandardized

Work

Leadership by Example amp Commitment

In-Station Process Control

Lean Measures

Employee Involvement amp Mutual Respect

Pull system flow production

Peak Performance

Variation reduction Six Sigma

Continuous Waste Reduction

Rapid Changeover Customer-driven lot size

7 Wastes

bull Transportationbull Excess productionbull Added processesbull Motion

bull Waitingbull Inventorybull Non-conformance (defectives)

Causes of Wastebull Excess Manning

ndash Poor layout and material presentationndash Rework and extra processes ndash Inconsistent inefficient work methods

bull Excess Downtimendash Tooling condition ndash Unreliable equipmentndash Long changeoversndash Incapable process

bull Defectives - Rework or Replacendash Incapable processes or process not compatible with

customer expectations or design spec (design for mfg)ndash Tooling conditionndash Operator methods and errors

Effective TPM Eliminates 5 Losses

1 Equipment breakdowns2 Defects scrap and rework3 Safety Issues4 Mini stoppages5 Reduced speed

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Operator Autonomous Maintenance

Countermeasures for Contamination

Initial Standards

General Inspection

Autonomous Inspection

Standardization

Aut MgtSeven Steps of TPM

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6

5

4

3

2

1Initial Clean-up

TPM is Planned Predictive amp Preventive

1 Starts with 5S Visual Factory2 Builds a comprehensive downtime data base

by cause frequency and duration3 Predicts and prevents downtime by PM

system 4 Expands role of Operator as first point of

early warning and prevention5 Professional Maintenance

5S Workplace

Sort (organize)

Shine (clean)

Set in order (make orderly and neat)

Standardize (visual place for everything)

Sustain (maintain the system)

A safe clean orderly workplace is fundamental to quality efficiency and teams

TPM starts with 5Sbull You canrsquot see problems clearly when the

workplace is in disarraybull Cleaning and organizing the workplace

helps the team to uncover problemsbull Making problems visible is the first step of

improvementbull Clean machines and workplace create pride

amp Safety

Downtime Visual Controls

bull Visual or audio alerts ndash Abnormality obvious at a glance (eg stoppage reject

control fault)ndash Alerting Maint and team leadersndash Provide real time ldquoscoreboardrdquo for employees

bull Machine down light visiblebull Production status board (eg actual counts vs goal)bull Scrap counts and downtime minutes bull Located in clear view in shop (not in control room)bull Simple self regulating amp employee managed


1 Starts with 5S Visual Factory2 Builds a comprehensive downtime

data base by cause frequency and duration

3 Predicts and prevents downtime by PM system

4 Expands role of Operator as first point of early warning and prevention

5 Professional Maintenance

Downtime Databasebull Categorize at a minimum by Equip Tooling CO Otherbull Segmented bar graph for E-T-O lost timebull Subcategories for Equip (eg)

ndash Hydraulic pneumaticndash Mechanical lubricationndash Electrical controlsndash Shot-end components

bull Subcategories for Tooling (eg)ndash Slidesndash Coresndash Insertsndash Ejector pins

bull Subcategories for Other (eg)ndash Operator errorndash Materials



by cause frequency and duration




Predictive Maintenance Toolsbull Ratehr vs target or historical normal output (BW)bull Database

ndash maintenance historyndash statistical probability (frequency amp duration)

bull Physical prediction of impending failurendash Sound (bearing)ndash Temperature (cooling water)ndash Flash (core pins) ndash Shot monitoring system ndash SPC on part geometry ndash Hydraulic pressure (ejector pins)ndash Spindle loads (amps) ndash Fluids Lubrication analysis (milipore)ndash Vibration Signature Analysis

Preventive Maintenance Systembull History of downtime by major machine amp tool

ndash Downtime measurement amp trackingndash Mean Time Between Failuresndash Average downtimendash Pareto of causes at component level (eg LS or temp sensor)ndash Cost to maintain

bull Develop PM cards based on frequency of failure and magnitude of average lost time (start small amp grow)ndash Limit amp prox switchesndash Shot tip sleevendash Critical frame and cylinder mounting boltsndash Expendable toolsndash Valves hoses packing seals

bull PMrsquos have instruction schedulefrequency amp sign-off ndash PMrsquos repairs done in window of opportunity when machine is downndash Cycle count or date based execution of PMrsquos (eg cutter change)ndash PM status visual (work completed not completed)

TPM is Planned Predictive amp Preventive1 Starts with 5S Visual Factory2 Builds a comprehensive downtime data base by

cause frequency and duration3 Predicts and prevents downtime by PM system

4 Expands role of Operator as first point of early warning and preventionbull One point lessons for operator awarenessbull Creates OMP (Operator - Maintenance

Partnership)bull Operator performs checks problem solving and

improvements5 Professional Maintenance

TPM

Production Operatorsbull Clean amp Checkbull Observebull Categorize

Manufacturing Engineersbull Equipment Planningbull Equipment Studies

Production Planning amp Control

bull Schedule PM

Quality Engineersbull Standards amp

Calibrations

ActivePlanned

MaintenanceProcess

OMP - Operator Maintenance Partnership

bull Operator training in TPMbull Operator basic equip inspection amp

tooling checksbull Operator basic cleaningbull Operator lubrication checkbull One point lessons (capture

knowledge)bull TPM Board amp TPM Tags (proactive

operator involvement)

TPM

TPM Tag System

bull Problem communication tool to and from maintenance tool room and productionndash Identify abnormal machine conditions

bull Record problem discovered by operatorbull Record problem found during scheduled PM

ndash Status tracking system of requested repairsndash TPM visual management tool (hang tags)ndash Repair history for future problem solving

bull TPM Tag used for recording problem amp fixndash Blue Tag-Operator or Maint responsible to repairndash Red Tag- Safety-related request (priority)

TPM is Proactive Predictive Preventive amp Planned




early warning and prevention


Professional Maintenance

bull Equip Safetybull Skill buildingbull Cross-trainingbull Area Maintenancebull Maint Mgmt Systembull Down alarmsbull Planned PM

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7



Prepare Temporary Standards

General Inspection


Standardization

Aut Mgt

7 Steps

7

6

5

4

3

2

1Initial Clean-up

OIL

T P M

TPM

5S

TPM IStep 1Step 2Step 3

TPM IIStep 4 Step 5Step 6Step 7

Initial Focus

prerequisite for TPM I

INTRODUCTION TO TOTAL PRODUCTIVE MAINTENANCE (TPM)

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Lean System

7 Wastes

Causes of Waste


Slide 41


5S Workplace

TPM starts with 5S


TPM is Planned Predictive amp Preventive (2)

Downtime Database


Predictive Maintenance Tools

Preventive Maintenance System


TPM


TPM Tag System



Slide 57

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Slide 63

Slide 64

What is TPM

Total Productive Maintenance (TPM) is a well-defined and time-tested concept for maintaining plants and equipment TPM can be considered as the medical science of machines

TPM was introduced to achieve the following objectives

1048707 Avoid waste in a quickly changing economic environment1048707 Produce goods without reducing product quality1048707 Reduce costs1048707 Produce a low batch quantity at the earliest possible time1048707 Send only non-defective parts to the customers

TPM involves all Denso Associates The major difference between TPM and other concepts is that the Production Operators are directly involved in the process of maintaining their equipment

The old notion of I operate the equipment You Maintain it is NOT followed































Pillars of TPM

Pillars of TPM

5S





TPM IMPLEMENTATION






Lean System

5S Visual Factory

T P MStandardized

Work



Lean Measures



Peak Performance




7 Wastes










1

2

3

4

5

6

7



Initial Standards

General Inspection


Standardization


7

6

5

4

3

2

1Initial Clean-up






5S Workplace

Sort (organize)

Shine (clean)









amp Safety

































TPM




bull Schedule PM


Calibrations

ActivePlanned

MaintenanceProcess






TPM

TPM Tag System













1

2

3

4

5

6

7




General Inspection


Standardization

Aut Mgt

7 Steps

7

6

5

4

3

2

1Initial Clean-up

OIL

T P M

TPM

5S



Initial Focus



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Lean System

7 Wastes

Causes of Waste


Slide 41


5S Workplace

TPM starts with 5S



Downtime Database





TPM


TPM Tag System



Slide 57

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Slide 59

Slide 60

Slide 61

Slide 62

Slide 63

Slide 64































Pillars of TPM

Pillars of TPM

5S





TPM IMPLEMENTATION






Lean System

5S Visual Factory

T P MStandardized

Work



Lean Measures



Peak Performance




7 Wastes










1

2

3

4

5

6

7



Initial Standards

General Inspection


Standardization


7

6

5

4

3

2

1Initial Clean-up






5S Workplace

Sort (organize)

Shine (clean)









amp Safety

































TPM




bull Schedule PM


Calibrations

ActivePlanned

MaintenanceProcess






TPM

TPM Tag System













1

2

3

4

5

6

7




General Inspection


Standardization

Aut Mgt

7 Steps

7

6

5

4

3

2

1Initial Clean-up

OIL

T P M

TPM

5S



Initial Focus



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Lean System

7 Wastes

Causes of Waste


Slide 41


5S Workplace

TPM starts with 5S



Downtime Database





TPM


TPM Tag System



Slide 57

Slide 58

Slide 59

Slide 60

Slide 61

Slide 62

Slide 63

Slide 64

Pillars of TPM

5S





TPM IMPLEMENTATION






Lean System

5S Visual Factory

T P MStandardized

Work



Lean Measures



Peak Performance




7 Wastes










1

2

3

4

5

6

7



Initial Standards

General Inspection


Standardization


7

6

5

4

3

2

1Initial Clean-up






5S Workplace

Sort (organize)

Shine (clean)









amp Safety

































TPM




bull Schedule PM


Calibrations

ActivePlanned

MaintenanceProcess






TPM

TPM Tag System













1

2

3

4

5

6

7




General Inspection


Standardization

Aut Mgt

7 Steps

7

6

5

4

3

2

1Initial Clean-up

OIL

T P M

TPM

5S



Initial Focus



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Lean System

7 Wastes

Causes of Waste


Slide 41


5S Workplace

TPM starts with 5S



Downtime Database





TPM


TPM Tag System



Slide 57

Slide 58

Slide 59

Slide 60

Slide 61

Slide 62

Slide 63

Slide 64





TPM IMPLEMENTATION






Lean System

5S Visual Factory

T P MStandardized

Work



Lean Measures



Peak Performance




7 Wastes










1

2

3

4

5

6

7



Initial Standards

General Inspection


Standardization


7

6

5

4

3

2

1Initial Clean-up






5S Workplace

Sort (organize)

Shine (clean)









amp Safety

































TPM




bull Schedule PM


Calibrations

ActivePlanned

MaintenanceProcess






TPM

TPM Tag System













1

2

3

4

5

6

7




General Inspection


Standardization

Aut Mgt

7 Steps

7

6

5

4

3

2

1Initial Clean-up

OIL

T P M

TPM

5S



Initial Focus



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Lean System

7 Wastes

Causes of Waste


Slide 41


5S Workplace

TPM starts with 5S



Downtime Database





TPM


TPM Tag System



Slide 57

Slide 58

Slide 59

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Lean System

5S Visual Factory

T P MStandardized

Work



Lean Measures



Peak Performance




7 Wastes










1

2

3

4

5

6

7



Initial Standards

General Inspection


Standardization


7

6

5

4

3

2

1Initial Clean-up






5S Workplace

Sort (organize)

Shine (clean)









amp Safety

































TPM




bull Schedule PM


Calibrations

ActivePlanned

MaintenanceProcess






TPM

TPM Tag System













1

2

3

4

5

6

7




General Inspection


Standardization

Aut Mgt

7 Steps

7

6

5

4

3

2

1Initial Clean-up

OIL

T P M

TPM

5S



Initial Focus



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Lean System

7 Wastes

Causes of Waste


Slide 41


5S Workplace

TPM starts with 5S



Downtime Database





TPM


TPM Tag System



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7 Wastes










1

2

3

4

5

6

7



Initial Standards

General Inspection


Standardization


7

6

5

4

3

2

1Initial Clean-up






5S Workplace

Sort (organize)

Shine (clean)









amp Safety

































TPM




bull Schedule PM


Calibrations

ActivePlanned

MaintenanceProcess






TPM

TPM Tag System













1

2

3

4

5

6

7




General Inspection


Standardization

Aut Mgt

7 Steps

7

6

5

4

3

2

1Initial Clean-up

OIL

T P M

TPM

5S



Initial Focus



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Lean System

7 Wastes

Causes of Waste


Slide 41


5S Workplace

TPM starts with 5S



Downtime Database





TPM


TPM Tag System



Slide 57

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1

2

3

4

5

6

7



Initial Standards

General Inspection


Standardization


7

6

5

4

3

2

1Initial Clean-up






5S Workplace

Sort (organize)

Shine (clean)









amp Safety

































TPM




bull Schedule PM


Calibrations

ActivePlanned

MaintenanceProcess






TPM

TPM Tag System













1

2

3

4

5

6

7




General Inspection


Standardization

Aut Mgt

7 Steps

7

6

5

4

3

2

1Initial Clean-up

OIL

T P M

TPM

5S



Initial Focus



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Lean System

7 Wastes

Causes of Waste


Slide 41


5S Workplace

TPM starts with 5S



Downtime Database





TPM


TPM Tag System



Slide 57

Slide 58

Slide 59

Slide 60

Slide 61

Slide 62

Slide 63

Slide 64






5S Workplace

Sort (organize)

Shine (clean)









amp Safety

































TPM




bull Schedule PM


Calibrations

ActivePlanned

MaintenanceProcess






TPM

TPM Tag System













1

2

3

4

5

6

7




General Inspection


Standardization

Aut Mgt

7 Steps

7

6

5

4

3

2

1Initial Clean-up

OIL

T P M

TPM

5S



Initial Focus



Slide 2

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Lean System

7 Wastes

Causes of Waste


Slide 41


5S Workplace

TPM starts with 5S



Downtime Database





TPM


TPM Tag System



Slide 57

Slide 58

Slide 59

Slide 60

Slide 61

Slide 62

Slide 63

Slide 64





amp Safety

































TPM




bull Schedule PM


Calibrations

ActivePlanned

MaintenanceProcess






TPM

TPM Tag System













1

2

3

4

5

6

7




General Inspection


Standardization

Aut Mgt

7 Steps

7

6

5

4

3

2

1Initial Clean-up

OIL

T P M

TPM

5S



Initial Focus



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Lean System

7 Wastes

Causes of Waste


Slide 41


5S Workplace

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Downtime Database





TPM


TPM Tag System



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TPM




bull Schedule PM


Calibrations

ActivePlanned

MaintenanceProcess






TPM

TPM Tag System













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Standardization

Aut Mgt

7 Steps

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OIL

T P M

TPM

5S



Initial Focus



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Lean System

7 Wastes

Causes of Waste


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5S Workplace

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Downtime Database





TPM


TPM Tag System



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TPM

TPM Tag System













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General Inspection


Standardization

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7 Steps

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OIL

T P M

TPM

5S



Initial Focus



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Lean System

7 Wastes

Causes of Waste


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5S Workplace

TPM starts with 5S



Downtime Database





TPM


TPM Tag System



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TPM Tag System













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General Inspection


Standardization

Aut Mgt

7 Steps

7

6

5

4

3

2

1Initial Clean-up

OIL

T P M

TPM

5S



Initial Focus



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Lean System

7 Wastes

Causes of Waste


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5S Workplace

TPM starts with 5S



Downtime Database





TPM


TPM Tag System



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1

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General Inspection


Standardization

Aut Mgt

7 Steps

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6

5

4

3

2

1Initial Clean-up

OIL

T P M

TPM

5S



Initial Focus



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Lean System

7 Wastes

Causes of Waste


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5S Workplace

TPM starts with 5S



Downtime Database





TPM


TPM Tag System



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TPM

5S



Initial Focus



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Lean System

7 Wastes

Causes of Waste


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5S Workplace

TPM starts with 5S



Downtime Database





TPM


TPM Tag System



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Lean System

7 Wastes

Causes of Waste


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5S Workplace

TPM starts with 5S



Downtime Database





TPM


TPM Tag System



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introduction to total productive maintenance (tpm)

Documents

maintenance group

maintenance prevention

routine maintenance

maintenance personnel

goal of productive maintenance

concept of daily maintenance

essential maintenance

tpm goals