which is the best pound for pound improvement strategy vs rcm.pdf · rsa inspired by change . . ....

Rolly Angeles

TPM vs RCM METHODOLOGY

Inspired by Change . . . RSA 2011

2011 All Rights Reserved Rev 5 : April 15, 2011

Which is the Best Pound for

Pound Improvement Strategy

Let’s Get Ready to

Rumble !

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Rolly Angeles



RCM and TPM are two of the most well know mainte-

nance and reliability improvement known to industries.

The results of this comparison are purely based on

the authors experience and knowledge with these two

power house improvement strategies and might differ

from other expert’s opinion. I have met independent

consultants on both TPM and RCM and asked for their

individual opinion regarding the other strategy. There

always seem to be some form of bias to whomever

you talk to. One can only understand which methodolo-

gies have an edge if you truly experience them both.

2011 All Rights Reserved

W A R N I N G

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RCM vs TPM SURVEY QUESTION

• Are you knowledgeable on TPM or RCM ?

Write the letter in a 1/8 piece of paper, and submit to the facilitator.

The result of the survey will be sum up and given as a percentage

of the class. Answer as honest as you can.

A) Yes, I know the concept of TPM only

B) Yes, I know the concept of RCM only

C) Yes, I know both TPM and RCM concept

D) Yes, I know both of them and we are currently

practicing both RCM and TPM

E) I have totally no idea what they meant

Answer honestly which letter do you think that best

fits your situation

Rolly Angeles



TPM Defined :

• TPM is a plant improvement methodology

which enables continuous & rapid improve-

ment of the manufacturing process through

the use of employee involvement, employee

empowerment and closed-loop measurement

of results

Implementing TPM by Robinson and Ginder

• It is a production driven improvement metho-

dology that is designed to optimize equipment

reliability and ensure efficient management of

Plant assets

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TPM Composed of 8 Pillars

Autonomous

Maintenance Production & Operations

Kobetsu-Kaizen - Cross Functional Teams

- Engineers and Process

Initial Flow

Control Activities - Purchasing Group

- RND Group

Admin / Office

TPM Administrative People

Environmental

Health and Safety EHS Department

Training and

Education Training Department

Planned

Maintenance Maintenance People

Quality

Maintenance Quality Control Group

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Goals of Each TPM Pillar

Planned Maintenance

- Attain Predictive Mtce Stage

- Increase MTBF reduce BDO to Zero

- Improve reliability & lower costs

- Establish Basic Equipment Condition

- Develop Standards for Lubrication,

Inspection and Cleaning

- Develop Empowered Operators

Autonomous Maintenance

- Attain 85% OEE on critical machines

- Elimination of 6 Equipment Losses

- Improve indices on PQCDSM

Focused Improvement

- Zero accidents and plant disasters

- Compliance to environmental stds.

Environmental, Health

and Safety (EHS)

Quality Maintenance

- Elimination of defects

- Elimination of chronic problems

Admin/Office TPM

- Reduce of Product inventory and

Work-In-Process

- Speed of Information transmission

Initial Flow Control

Activities (IFCA) - Well develop system of MP Design

- Improvement in Vertical Start-up

time of equipment being purchase

Training and Education

- Effective training skills assessment

- Systematic training programs

- Training's are used religiously

Zero Breakdowns

Zero Accidents

Zero Defects

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TPM 12 Developmental Step by Step Approach

Stage Step

Preparatory 1. Declaration of Top Management to introduce TPM

2. Conduct TPM Educational Campaign

3. Create a TPM promotional organization

4. Establish TPM Basic Policy and Goals

5. Create a Master Plan of Implementing TPM

Introduction 6. Kick-off TPM

Implementation 7. Establish system to improve Production Efficiency

7.1 Implement Kobetsu-Kaizen Pillar

7.2 Implement Autonomous Maintenance Pillar

7.3 Implement Planned Maintenance Pillar

7.4 Training & education for operation and mtce

8. Build an Initial Flow Control Activities

9. Build a Quality Maintenance System

10. Implement Admin./Office TPM for support system

11. Establish a system for effective EHS

Stabilization 12. Total TPM implementation and raise level

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RCM EVOLVEMENT FROM THE AIRLINE INDUSTRY

• Reliability-Centred Maintenance find its roots in work done by the

international commercial aviation industry

• Driven by the need to improve reliability while containing the cost of

maintenance, this industry develop a comprehensive process for

deciding what maintenance work is needed to keep aircraft airborne.

This process evolved steadily in its early beginning during the 1960’s

• This process is still being used up to this day to determine the required

maintenance task for their assets for the commercial aviation industry

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Reliability -Centred Maintenance : is a process used

to determine the maintenance requirements of any

physical asset in its operating context.

Reliability -Centred Maintenance : is a process used

to determine what must be done to ensure that any

physical asset continues to do whatever its users

want it to do in its present operating context.

LIGHTER DEFENITION :

7 BASIC RCM QUESTIONS :

1. What are the functions and associated performance standards of the asset in its

present operating context ?

2. In what ways does it fail to fulfill its functions ?

3. What causes each functional failures ?

4. What happens when each functional failure occurs ?

5. In what ways does each failure matter ?

6. What can be done to predict or prevent each failure ?

7. What should be done if a suitable proactive task cannot be found ?

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1 How it is being approached

ROUND RCM TPM RESULTS POINT OF COMPARISON

2 Primary Measure of Performance

3 What is Believes

4 Goal on Maintenance

5 Operators Involvement on Mtce

6 On Continuous Improvement

7 RCM and TPM Initial Approach

8 Plant Involvement

9 Focus on Maintenance

10 Applicability on Industries

11 Flexibility of combining the two

12 What it wants to Achieve

Overall Tabulation Result

YOUR SCORESHEET

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How To Score this Bout

• 3 knockdown rule is not in effect

• Only referee can stop the fight

• Judges to use the 10 point must

system

• There will be no standing 8 count

• Judge to score 10 points for the winner

of the round and 9 points for the loser

• In case of knockdown, opponent to wait

at a neutral corner, and judge to score

10 points for the winner and 8 for the

loser of the round

• In case of a knockdown, the fighter

cannot be saved by the bell in any round

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TALE OF THE TAPE

Seiiji Nakajima Father of TPM

John Moubray Develop RCM for Industries

Height : Smaller than Moubray Height : Taller than Nakajima

Weight : Lighter than Moubray Weight : Heavier than Nakajima

Age : Older than Moubray Age : Younger than Nakajima

12 rounds for the Undisputed Heavyweight Reliability and

Maintenance Improvement Championship of the World

RED CORNER BLUE CORNER

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How It is being Approached

• Without management commitment it is very

difficult for TPM to succeed. On the other hand,

RCM is much easier to implement than TPM.

This makes it easier for RCM to be implemented

than TPM.

With regards to approach RCM have an

edge on TPM.

• One of main difference in approach regarding

these two improvement initiatives is that TPM

is always a Top-down approach and a plant

wide improvement initiative while RCM can be

done from on a bottom-up approach.

RCM TPM

10 points 9 points

I give this round to RCM.

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• If the equipment Availability is 100%, is the equipment said to be

at its peak and reliable ? Answer : NO, The equipment may be 100% AVAILABLE but have a low

UTILIZATION or have not been utilized at all, hence utilization is not a

measure of reliability but only when the machine is used

• If the equipment Availability & Utilization is 100%,

is the equipment said to be at its peak & reliable ?

Answer : NO, The equipment may be 100%

utilized and available but the machine may

suffer from errors and speed loss. Example

a machine speed may be reduced so as not

to deliver problems in quality.

• If the equipment OEE is 90%, is the equipment said to be reliabile?

Answer : NOT EXACTLY, OEE is not about achieving 85% or more but

about satisfying the 3 components, in the case below the equipment is

suffering from a large rate of defects.

OEE = 100% (Utilization) x 97% (Efficiency) x 93% (Yield) = 90.21%

Primary Measure of Performance 2

No Reason for celebration


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• There is often a tendency to focus too heavily on primary functions when

assessing maintenance effectiveness. This is a mistake because in prac-

tice trivial secondary functions often embody bigger threats to the orga-

nization if they fail than primary functions.

As a result, every function must be consi-

dered when setting up the maintenance

effectiveness measures and targets

From page 302 of the book Reliability-Centred Maintenance by John Moubray

• The OEE as defined above only relates to

the primary function of any asset. This is

misleading because as in the case of the

gasoline storage system, every asset,

machine tools included have many more

functions than the primary function and

each of these functions have their own unique performance standards,

consequently OEE is not a measure of the overall effectiveness at all but

only a measure of the effectiveness with w/c the primary function of the

asset is being fulfilled. . . .

From page 304 Reliability-Centred Maintenance by John Moubray



Rolly Angeles



The main indices used to measure TPM performance is Overall Equipment

Effectiveness. OEE is computed by multiplying its three components which

are Availability, Performance Rate and Quality Rate. OEE addresses the 6

major equipment losses encountered on the equipment which includes

breakdowns, set-up and conversion, start-up losses, idling and minor

stoppages, design speed loss, defect and rework losses.

For RCM, the main measure of perfor-

mance used is MTBF which is mostly

related to breakdowns and equipment

failures. Although OEE is not a perfect

measurement as explained in pages 91

to 92 of my book on WCM, the scope

of OEE is much larger than MTBF since

MTBF only covers one part of the equip-

ment losses which is breakdown, while

OEE covers the 6 major equipment

losses.



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Having a high OEE does not gua-

rantee that the equipment is in-

deed reliable. Since OEE is only

focused on the primary function

of the equipment. Meaning as

long as output is high, quality is

good and the equipment is uti-

lized then OEE will be high. But

every equipment has both its

primary and secondary functions

and OEE is only focused on the

primary function of the equipment. But comparing these two primary

measurements, OEE is still wider in

scope than MTBF, since failures and

breakdowns are just a subset of OEE.

RCM TPM

9 points 10 points A flurry of punches by TPM and RCM

is hurt.


I give this round to TPM.


Rolly Angeles



What it Believes 3

RCM TPM

10 points 9 points

TPM believes that in order to advance to any improvement

initiative, basic equipment condition must be carried out first.

On the other hand, RCM states that

the first step is to change the way

people think and apply this change

Thoughts to their asset. RCM has

a valid point because even before

basic equipment condition should

be established both operators and

maintenance should change the

way they think about their equip-

ment and build this new way of

thinking as part of their culture.

A cracking left and right to the jaw by

RCM. RCM wins this round.


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Goal on Maintenance

TPM goal is to zero out unplanned

breakdowns, while RCM goal is not

about eliminating breakdown but

understanding that each failure has

its own unique set of consequences

and if the consequences of the failure

is not acceptable then all effort must

be exhausted in order to reduce its

likelihood.

4

TPM goal is somewhat idealistic. In reality

what TPM is actually doing is not actually

eliminating breakdown but increasing the

MTBF of the equipment by adhering to the

basic equipment condition and lengthe-

ning the life of parts with inherent design

weaknesses


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RCM TPM

10 points 9 points

Maintenance is not about zeroing

out or eliminating failures but simply

trying to understand that it is more

important to understand the conse-

quences of failure rather than elimi-

nating the failure completely. In

reality, it is impossible to zero out

breakdowns.

A left hook and uppercut and TPM

is stunned.

Goal on Maintenance 4

What maintenance can do is simply

to anticipate, prevent, predict, con-

trol or prolong the duration of failure.

RCM explanation here is much com-

prehensive than TPM.

I give this round to RCM.

Department A = 10 BDO for April 2011

Department B = 1 BDO for April 2011

Which is the better department ?

In Dept. B what failed was the substation!


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Operators Involvement on Maintenance

Both RCM and TPM believes that operators

should be involved in maintenance. In any

RCM analysis, operators must be part of the

team doing the analysis since RCM believes

that it is the operators and not maintenance

that have direct contact and have witnessed

the failure.

One of the pillars of TPM is Autonomous

Maintenance which is done through a

detailed and structured 7 steps approach.

Maintenance teaches operators about

their own quipment and operators learn

not only to operate but also to take good

care of its equipment by understanding

what to clean, inspect and lubricate.

5


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RCM TPM

9 points 10 points

Operators Involvement on Maintenance

Autonomous Maintenance pillar let

operators understand that they, too,

have a role in maintaining their own

equipment by performing the basics

such as cleaning, lubrication and

checking for loose and incomplete

bolts on their equipment. In short,

the role of operators role is much

more detailed and structured in TPM

than RCM.

5

Left, right to the jaw, TPM connects,

RCM is staggered. I definitely give

this round to TPM.


Rolly Angeles



Its Belief on Continuous Improvement

On the other hand RCM focuses its

strength on adopting a robust and

structured approach about the correct

way to maintain the equipment by

assigning a tasks on all possible failure

modes that can affect the equipment

and adopting the most feasible mainte-

nance tasks to use with the aid of a

decision diagram or an algorithm.

This round is where TPM and RCM

have some forms of different point

of view. TPM is heavy on improve-

ments. TPM believes that the

equipment should be continuously

improved,

6


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There is a thin line between improving the equipment and maintaining

the equipment. There are times that we improve or modify the equipment

only to learn that the equipment will be decommissioned because of

obsolescence. Most improvements take time to accomplish. Some may

even take several months, hence a person who is on duty today has to

maintain the equipment as it exists today and not what it should be there

in the future.

Before considering improving or modifying the

equipment, have we asked ourselves if the asset

is here to stay for a long time or will it be deco-

mmissioned. Hence, before trying to improve or

redesign the equipment we must have a concrete

answer to these questions.

Its Belief About Continuous Improvement

I believe this round belongs to

RCM.

RCM TPM

10 points 9 points

6

I give RCM this round.


Rolly Angeles



RCM and TPM Initial Approach

RCM TPM

9 points 10 points

7 RCM starts by determining the asset

functions and failure modes, while

TPM believes in addressing equip-

ment basic condition first. Many

failures start with small things and

it is from these small things which

are often left neglected that cause

big problem.

Big problems are just an accumulation

of small problems. TPM believes that big

failures can be prevented if we address

the basics. In fact some of the failure

modes can be reduced if basic equipment

condition is well established on the asset

A flurry of punches and RCM is down on

the ropes. I give TPM credit for this round.


Rolly Angeles



Plant Involvement

RCM TPM

9 points 10 points

TPM will involve everyone from the organiza-

tion, from the Top down to the shopfloor.

Each will have their own TPM pillar to be

busy about. Even people from offices will

be involved in Office/Admin TPM.

On the contrary, RCM involvement would be

limited to maintenance, operators with the

most extensive knowledge on their assets,

and from time to time vendors mostly who

have direct impact on the equipment being

analyzed. I doubt if HRD or the finance

department can be involved directly in an

RCM analysis.

Again, as for plant involvement, I give this round to TPM. At this point of

the round both RCM and TPM are dead even with a score of 76 points.

Wicked left hook by TPM, RCM is staggered and the crowd is wild on its

feet.

RCM is like an Elite Delta Force

TPM is for everyone while RCM Is not

8

TPM wins this round.


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Focus on Maintenance

RCM TPM

10 points 10 points

9 TPM focuses on addressing the six big equipment losses. By reducing

these equipment losses OEE will improve. On the other hand RCM focuses

on both primary and secondary functions of the equipment.

RCM highlights the importance of secondary functions of the equipment.

It allows us to understand that there are cases where failure of secondary

functions poses a bigger treat rather than the failure of the primary function.

I think both RCM and TPM have good points

on this. Both fighters standing toe to toe,

no one is backing out. . This round is a draw


Rolly Angeles



Applicability on Industry

RCM TPM

10 points 9 points

10 Speaking about its applicability to industries, RCM has an edge on this

as its process can be applied and can suit mostly any type of industry

from the nuclear, oil and gas, mining, metals, manufacturing, power plants,

assembly plants, airline industry, where it originated, shipping, automo-

tive, as long as there are equipment and assets to be maintain.

TPM application is mostly suited for

manufacturing industries. I just won’t

recommend TPM to be used for the

oil and gas sector or the airline

industries unless we have a way of

measuring the bad molecules on oil

so that OEE can be calculated. TPM

is a good improvement strategy, but

it is not fit for use for these industries.

Hence, for industry application, I think

RCM is more diversified to use than

TPM. I’ll give this round to RCM.

Can you perform initial cleaning here !


Rolly Angeles



RCM TPM

9 points 10 points TPM wins this round

If we buy a pizza, TPM itself is the whole

pizza, while RCM is just a of the pizza. I

see RCM fit perfectly into the higher

phases of Planned Maintenance which

is one of the major pillars of TPM.

In fact, several TPM case studies include

doing RCM on its equipment through the

higher phases of Planned Maintenance.

In view of this, TPM is more flexible than

RCM.

There is no mention of alignment to other improvement initiatives in the

report by Stanley Nowlan and Howard Heap nor from the book by Moubray

on RCM. RCM also provides a standard SAE JA1011 to differentiate its

RCM from other streamlined versions.

11 Flexibility of Combining TPM and RCM


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What it wants to Achieve in Maintenance 12 TPM will aim for Maintenance Prevention while RCM goes for Proactive

Maintenance. TPM is more idealistic, since in reality, we really cannot

eliminate maintenance. Our equipment is not a plug and play asset where

we expect it to be reliable all the time. TPM wants us to think about an

ideal plant with zero breakdown, accidents and defect, and what it takes

for us to bring our plant closer and closer to it.

An ideal plant has been chosen by TPM

so that its people will aim to continuous-

ly improve. TPM does not want us to re-

main in the same, but to improve gra-

dually step by step, drip by drip.

People believe that TPM is a continuous

journey, and if they have one word that

is out of their vocabulary, it is the word

best, because TPM believes that the

best can still be made better.


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12 On the contrary, RCM aims for being Proactive,

finding the most suitable maintenance tasks for

each failure mode uncovered, doing RCM increa-

ses the assets integrity by considering both en-

vironmental and safety implications before con-

sidering its effects on operations.

RCM believes that maintenance is about under-

standing the consequences of failure rather

than eliminating the failure itself. Both RCM

and TPM clearly explain what they want to

achieve in maintenance and that the key to

all this will be their people. If people change,

the culture will change and their assets will

be improved.

With less than a minute left in the bout, both fighters give it all. Both

fighters in the middle of the ring toe to toe, hitting each other with every-

thing they got, a bridge to the nose and the bell ends, the crowd wild on

its feet, probably one of the best match ever. This round is a draw !

What it wants to Achieve in Maintenance


Rolly Angeles



TPM vs RCM SURVEY QUESTION

• Which do you think have an edge RCM or TPM ?

Write the letter in a 1/8 piece of paper, and submit to the facilitator.

The result of the survey will be sum up and given as a percentage

of the class. Answer as honest as you can.

A) I think RCM have definitely have an edge

over TPM. RCM wins this bout.

B) I think TPM have definitely an edge

over RCM. TPM wins this bout

C) I think neither one have an edge since

both of them are not contradictory. This

bout is a draw

D) I do not know which one has an edge, I am

just here to listen. No comment on the bout

Answer honestly which letter do you think that

best fits your situation

Rolly Angeles



1 How it is being approached 10 9 RCM wins

ROUND RCM TPM RESULTS POINT OF COMPARISON

2 Primary Measure of Performance 9 10 TPM wins

3 What is Believes 10 9 RCM wins

4 Goal on Maintenance 10 9 RCM wins

5 Operators Involvement on Mtce 9 10 TPM wins

6 On Continuous Improvement 10 9 RCM wins

7 RCM and TPM Initial Approach 9 10 TPM wins

8 Plant Involvement 9 10 TPM wins

9 Focus on Maintenance 10 10 Draw

10 Applicability on Industries 10 9 RCM wins

11 Flexibility of combining the two 9 10 TPM wins

12 What it wants to Achieve 10 10 Draw

Overall Tabulation Result 115 115 Draw

Rolly Angeles



TPM and RCM may have different origins but these two heavyweight

maintenance methodology are not contradicting but rather they are

complementary. It is the individual consultants that do the contra-

diction and not the methodologies

Is TPM and RCM Contradictory or Complementary ?

Rolly Angeles



I would like to express my thanks

to you for taking time to view this

brief presentation on TPM vs RCM

(Thank You)

Website : http://www.rsareliability.com

Email : [email protected]

Mobile : +63920-924-6163

Tel No. : +6349-502-66-57

http://www.rsareliability.com/

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