TPM Third Country TC-print 1

Total Productive Maintenance(TPM)

László Soós

TPM Third Country TC-print 2

OUTLINE

Types of maintenance

Total maintenance system

The six big losses reduce the efficiency

The 5 causes of breakdown

Breakdowns and reliability

The importance of the loss deployment

TPM Third Country TC-print 3

PEOPLE, EQUIPMENT, TECHNOLOGY

In the competitive environment the technology is the physicalmanifestation of the knowledge.

TECHNOLOGY

CADComputer ModelingCNC MachinesAssembling robotsAutomatic ControlAutomatic store…..

HOW THE TECHNOLOGYEFFECT THE BUSINESS

Design Easy to sell productProduction Required quality Operation Low cost Delivery Short lead time

MAINTENANCEIt makes easy for the technology to perform appropriate effect for business

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OPERATION UNTIL BREAKDOWN

PREVENTIVE MAINTENANCE

TPM

CONDITION BASEDAGAINST BREAKDOWN

TIME BASED

COMPANY WIDEDOING BY THE PRODUCTION &

MAINTENANCE

NO MAINTENANCE, ONLY REPAIR

-1950

1950-

1970-

REPAIR

REPAIR

TYPES OF THE MAITENANCE

164 COMPANIES WON TPM AWARDS FOR THE EXCELENT PLANT MAINTENANCE IN 2003(JIPM Japan Institute of Plant Maintenance)

Breakdown can happen any time

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BREAKDOWN REPAIR

PREVENTIVEMAINTENANCE

(PROFESSIONAL)

WHEN?HOW?

TIME BASED

CONDITION BASED

FAILUREDETERMINATION

OILING LUBRICATION

CLEANING

PRACTICE

VIBRATIONTRIBOLOGY

TEMPERATUREELECTRICAL

RELIABILITY BASED

MAINTENANCE

TPM

AUTONOMOUSMAINTENANCE CONTINUOUS

IMPROVEMENT

GENERAL REPAIR

OPERATIONUNTIL

BREAKDOWN

MAITENANCE POLICY

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TOTAL MAINTENANCE SYSTEM

Professionalmaintenance

Autonomousmaintenance

REPAIR

PREVENTIVE MAINTENANCE

CLEANING, LUBRICATION

PAYING ATTENTION TO ABNORMALITY

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TPM ( TOTAL PRODUCTIVE MAINTENANCE )

TPM is an acronym of Total Productive Maintenance and

its more advanced form Total Productive Management.

TPM combines the American Preventive Maintenance practice and the Japan Total Quality Control.

The result is an innovative system what optimizes the efficiency, prevents machine breakdowns and support the autonomous maintenance in the daily practice.

What is TPM ?

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TPM ( TOTAL PRODUCTIVE MAINTENANCE )

The scope of TPM

⇒ Reduction of the machine breakdown

⇒ Reduction of the repair time

⇒ Quality improvement

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TPM ( TOTAL PRODUCTIVE MAINTENANCE )

� TPM target is to maximize the efficient usage of the machine during the whole lifecycle.

� The operation of TPM needs the involvement of all organization units at all level.This motivates the teamwork and the autonomous activity.

� TPM includes the improvement of the operational/maintenance system, the implementation of the good housekeeping, the improvement ofthe problem solving ability to be achieve the “ZERO” breakdown, „ZERO” Accident, „ZERO” defect.

� Top management should prepare an evaluation system.

� Based on the evaluation system the ability and responsibility ofthe employee should be appreciated and/or rewarded.

The targets and features of TPM

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Operator = Operates themachine

Maintenance = Maintenanceperson +

repair

Engineer = Production cycle planning

Conventional maintenance

Daily checkingObserve the abnormalityCleaning and lubrication

Quality knowledge

Maintenance planningPlanning for easy maintenance

TPM

=

SUPPLEMENTATION OF THE CONVENTIONAL MAINTENANCE

Requirements for the company: high level Production & Quality

Multi qualificationCreativityChanging job

+

+

+

Requirements for the employees

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THE SIX BIG LOSSES REDUCE THE EFFICIENCY

1! BREAKDOWN

2! SET UP & ADJUSTMENT

3! SPEED LOSS

4! SHORT STOPS, IDELING

5! START UP LOSS

6! DEFECT & REWORK

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THE 6 BIG LOSSES AND „OEE” AS THE MAIN INDICATOR

Value addedhours

Defectloss

Net utilization hours Speedloss

Utilization hours Downtimeloss

Loading hours Planneddowntime

Theoretical available planned time

Training,Events

1. Breakdown2. Set up, adjustment

3. Short stops / Idling loss4. Reduced speed

5. Quality loss6. Start-up

Loading hours – DowntimeLoading hours

Standard cycle time x Processed unitUtilization hours

Processed unit – Def. uProcessed unitsXX

Overall Equipment Efficiency (OEE)

AVAILIBILITY PERFORMANCE RATE QUALITY RATE

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THE 5 COUSES OF BREAKDOWNS

Machine basic poor condition

Lack ofskill

PoorDesign

Poor operation conditions

Lack of restorationof deterioration

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BREAKDOWN PREVENTION

1. GUARANTEE THE BASIC CONDITIONS:

- MACHINE CLEANING AT THE SOURCE OF THE DIRT

- TIGHTENING FIX LOOSENING

- OILING FILLED VOLUME LIST

- STANDARDS CLEANING & LUBRICATION

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BREAKDOWN PREVENTION

2. KEEPING THE OPERATION CONDITIONS

- DEFINE THE PLANNED CAPACITY AND THE LOAD LIMIT

- OPERATION METHOD STANDARDIZATION

- DEFINITION AND IMPROVEMENT OF THE USAGE CONDITIONS OF THE PARTS & UNITS

- DEFINITION OF THE PIPES & CABLES

- IMPROVEMENT OF THE IMPLEMENTATION INSTRUCTIONS

- PROTECTION AGAINST DUST AND WATER AT THE SLIDING & TURNING PARTS

- GUARANTEE THE ENVIRONMENTAL CONDITIONS IN TERMS OF DUST, TEMPERATURE, HUMADITY AND VIBRATION

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BREAKDOWN PREVENTION

3. RESTORE THE DETERIORATION

- BIG CHANGES ARE RECOGNISED – SMALL CHANGES (DETERIORATION) SOMETIMES ARE OVERLOOKED BUT CAN MAKE SPORADIC BREAKDOWNS

- DETERIORATION SHOULD BE MONITORED

- THE NEGLECTED ACTIONS MUST BE DONE CLEANING, OILING

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BREAKDOWN PREVENTION

4. IMPROVE THE MAINTENANCE

- ANALIZE THE BREAKDOWNS

- ESTABLISH A PREVENTIVE MAINTENANCE SYSTEM

- DEFINE STANDARDS FOR THE MAINTENANCE ACTIVITY

- TRAIN THE MAINENANCE STAFF AND OPERATORS

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BREAKDOWN PREVENTION

5. IMPROVE THE CONSTRUCTION

- IF THE RESTORATION IS NOT ABLE TO REDUCE THE FAILURES TO ZEROAND MAINTENANCE COST WILL INCREASE, IT IS NECESSARY TO CHANGE THE MACHINE DESIGN

- STEPS OF THE DESIGN CHANGING:- UNDERSTAND THE STATE OF THE MACHINE BEFORE AND AFTERFAILURE

- STUDY THE STRUCTURE AND THE FUNCTION OF THE MACHINE

- BE SURE THAT ALL OF THE DESIRED CONDITIONS WEREIMPLEMENTED ON A PROPERLY WAY

- ANALYSE THE CAUSES

- DEVELOPE AN IMPROVEMENT PLAN

- IMPLEMENT THE PLAN AND MONITOR THE RESULT

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BREAKDOWNS AND RELIABILITY

MTBF indicator Mean Time Between Failures

MTTR indicator Mean Time To Repair

TBF1

Stopingt1 t2 t3 t4 t5 t6 t7 t8

TTR1

Performance

Working

TTR2

MTBF = TBF1 + TBF22

TBF2

DT2

MTTR = TTR1 + TTR2

Time

DT1

2

DT Downtime

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POINTS OF THE QUICK RESTORATION (After a breakdown occurs)

Information flow

Parts reserve

Parts store

Parts suppliers, service contracts

Storing of the repair tools

Skills training

Placement

Arrangement

Indication

Placement

Arrangement

Indication

Org

aniz

atio

nTT

R

Dow

ntim

e

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PROFIT - PRODUCTIVITY - EFFICIENCY

Indicators forthe six big losses

Availability rate

Performance rate

Quality rate

x

x

Loss analysis

BREAKDOWN

Frequency

Analyzethe 5 main causes of

the machine breakdown

Length

Analyze the cause of

the long repair time

1. Machine basic poor condition2. Poor operation conditions3. Lack of restoration of deterioration4. Poor design5. Lack of skill

Operational failure

1.Spare part2.Organiz.3.Tools4.Training

occurrence/week min/occurrencex

OEE12

34

56

DEPLOYMENT

Maintenance failure

BreakdownSet up, adjustShort stopReduced speedQuality lossStart up loss

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TOTAL PRODUCTIVE MAINTENANCE

MANAGEMENT PILLARSA

uton

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Plan

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Mai

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ance

Con

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us Im

prov

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Initi

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Man

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Skill

Dev

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TPM