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7/29/2019 SMRPchapter-Ginder

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Introduction: TPM

Presented by Andy GinderVice President, ABB Reliability

Consulting281-450-1081

[email protected]


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Objectives

Learn the main elements and features of TPM

Know the stages and steps of a TPM program and their

purpose, and appreciate the benefits of the process

Understand how preventive maintenance, 5S, SMED and

other activities apply to TPM Understand how the feedback process works, and how

equipment effectiveness is measured


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Total Productive Maintenance

A plant improvement methodology Enables continuous and rapid improvement of the

manufacturing process

Extensive use of employee involvement, employeeempowerment Small groups

Closed-loop measurement of results. Key performance measures or indicators provide feedback

to the process to support continuous improvement

OEE


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Equipment Reliability

The probability that equipment or systems willperform required functions satisfactorily under

specific conditions within a certain period of time. Intrinsic: based on design Determined during the design, fabrication, and

installation stages. Operational: determined by the user

Related to how and under what conditions the

equipment is operated and maintained.


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Evolution of TPM


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Feedback and Measurement


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Check Examine and Exposeproblems

Ac t Counter & Solve problemsPlan Prevent recurrence throughimprovement

Do Execute & follow standards &rules

P

A

D

Optimal ConditionsOptimal Conditions

C

C

A

P

D

C

A

Check

Act

Plan

Do

Autonomous Maintenance Approach

C

A

P

D


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Core Elements of TPM

Paradigm shift from the typical perceptions of who isresponsible for maintenance.

Maximize overall equipment effectiveness.

Establish a thorough maintenance system for the entire lifespan of the equipment.

Implement by all departments including engineering,

operations, maintenance, environmental, purchasing,accounting, stores, safety, and human resources.

Involve every employee, from top management to hourly

employees.


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TPM Program Stages (4)

Stages

I. Preparation

II. Preliminary Implementation

III. TPM Implementation

IV. Stabilization


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TPM Program - 12 Steps

Stage I. Preparation1. Formulate master plan for TPM implementation

2. Announce top managements decision to

introduce TPM3. Launch education program and campaign to

introduce TPM

4. Create organizations (teams) to promote TPM

5. Establish basic TPM policies and goals


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The TPM Goals/Process

Define the Vision - Should be a Stretch Goal

Create the Mission Statement Minimal: Concise, short and sweet

Memorable: A rallying cry

Measurable: You know when you have arrived,a concrete step toward attainment of your vision

Define Core Values Develop Strategies

Create Key Performance Indicators

Define Critical Activities


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Stage II. Preliminary Implementation6. Hold TPM kick-off

Stage III. TPM Implementation

7. Improve effectiveness of each piece ofequipment

8. Develop an operator performed maintenance

program

9. Develop a scheduled maintenance program for

the Operations and Maintenance departments


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Sample Operator Tasks

Housekeeping andcleaning equipment

Visual checks andinspections

Changing filters

Dismantling obsoletepiping and tubing

Removing insulation

Tightening looseconnections, hardware,

belts

Repairing steam leaks

Adjusting valve packings

Greasing valves

Installing line clamps

Doing minor painting


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Criteria for Selecting Operator

Tasks Safety

Time requirements Task receptivity

Task timing

Task complexity

Task frequency

Task criticality Training requirements

Tool and material

requirements


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Support Tools Basic hand tools Detailed inspection sheets or checklists

Equipment logs Specific written procedures Visual graphics, routes, diagrams

Color coding (marked lube points), equipmentnumbers

Equipment markings or stamped plates

Operator backlogs and performance indicators


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Stage III. TPM Implementation (cont)

10. Conduct training to improve operation andmaintenance skills

11. Develop equipment management ormaintenance prevention program

Stage IV. Stabilization

12. Perfect TPM implementation and raise TPM

levels


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Sustaining the Process

Self-Sustaining is a Myth. Requirements are: Active Champions and Sponsors

Knowledgeable and Motivated People

A Holistic Strategic Approach Supported by TacticalPlans

Emphasis on Practical (Real-World) Application ofTheoretical Concepts

Ongoing Internal Reinforcement

Integrated with Appropriate Rewards and Incentives

Supplemented by Periodic External Interventions

Backed by Audit Process


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What is 5S?

A process designed to organize the

workplace, keep itneatandclean, maintain

standardizedconditions, and instill thediscipline required to enable each

individual to achieve and maintain a world

class work environment.


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What are the 5Ss?

1. SEIRI - Sort

2. SEITON - Set in order

3. SEISO- Shine

4. SEIKETSU - Standardize

5. SHITSUKE- Sustain


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Before

After


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Evolution Intangible Benefits

Clean Environment


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SMEDSMEDSMED: Single-Minute Exchange ofDie

Internal Setup: Operations that are

performed while a machine is stopped External Setup: Operations that are

performed while a machine is running

SMED was originally designed to improve die presssetups but its principles apply to changeovers in all

types of processes


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3 Phases of SMED

Separating Internaland External Setup

Converting InternalSetup to External

Setup Streamlining all

Aspect of the Setup

Operation

SMEDSMEDSMED


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Preventive Maintenance

PM Analysis Procedure

Clarify the problem

Conduct a physical analysis of the problem

List every condition potentially related to theproblem

Evaluate equipment, materials, and methods

Plan the investigation Investigate malfunctions

Formulate improvement plan


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Preventive Maintenance andMaintenance Standards

Maintenance StandardsA. Equipment maintenance standards

1. Inspection standards for measuring equipment

deterioration2. Overhaul standards for preventing equipment

deterioration

3. Repair standards for restoring equipmentB. Maintenance work procedures

1. Procedures showing work practices and times


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Questions

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