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Total Productive Maintenanceand Maintenance Managementhttp://www.managementsupport.comTotal Productive Maintenanceand Maintenance Managementhttp://www.managementsupport.com
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OutlineOutline
What is Total Productive MaintenanceWhat is Total Productive Maintenance
Origins of TPMOrigins of TPM
TPM PrinciplesTPM Principles
Components of TPMComponents of TPM
Autonomous MaintenanceAutonomous Maintenance
Planned MaintenancePlanned Maintenance
Equipment & Process ImprovementEquipment & Process Improvement
Early Management of New EquipmentEarly Management of New Equipment
Process Quality ManagementProcess Quality Management
TPM in the OfficeTPM in the Office
Implementing TPMImplementing TPM
TPM BenefitsTPM Benefits
Maintenance Management & StrategyMaintenance Management & Strategy
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What is TPMWhat is TPM
A company-wide team-based effort to build quality into equipmentand to improve overall equipment effectivenessA company-wide team-based effort to build quality into equipmentand to improve overall equipment effectiveness
TotalTotal
all employees are involvedall employees are involved
it aims to eliminate all accidents, defects and breakdownsit aims to eliminate all accidents, defects and breakdowns
ProductiveProductive
actions are performed while production goes onactions are performed while production goes on
troubles for production are minimizedtroubles for production are minimized
MaintenanceMaintenance
keep in good conditionkeep in good condition
repair, clean, lubricaterepair, clean, lubricate
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Autonomous MaintenanceAutonomous Maintenance
7 steps are implemented to progressively increase operatorsknowledge, participation and responsibility for their equipment7 steps are implemented to progressively increase operatorsknowledge, participation and responsibility for their equipment
1. Perform initial cleaning and inspection1. Perform initial cleaning and inspection
2. Countermeasures for the causes and effects of dirt and dust2. Countermeasures for the causes and effects of dirt and dust
3. Establish cleaning and lubrication standards3. Establish cleaning and lubrication standards
4. Conduct general inspection training4. Conduct general inspection training
5. Carry out equipment inspection checks5. Carry out equipment inspection checks
6. Workplace management and control6. Workplace management and control
7. Continuous improvement7. Continuous improvement
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Early Management of New EquipmentEarly Management of New Equipment
Objective: establish systems to shortenObjective: establish systems to shorten
new product or equipment developmentnew product or equipment development
start-up, commissioning and stabilization time for quality andefficiencystart-up, commissioning and stabilization time for quality andefficiency
New equipment needs to be:New equipment needs to be:
easy to operateeasy to operate
easy to cleaneasy to clean
easy to maintain and reliableeasy to maintain and reliable
have quick set-up timeshave quick set-up times
operate at the lowest life cycle costoperate at the lowest life cycle cost
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7: Develop Equipment Management Program7: Develop Equipment Management Program
The tools of Total Quality Management and ContinuousImprovement are applied to the management andimprovement of equipmentThe tools of Total Quality Management and ContinuousImprovement are applied to the management andimprovement of equipment
Form project teamsForm project teams
Select model equipmentSelect model equipment
identify equipment problemsidentify equipment problems
analyze equipment problemsanalyze equipment problems
develop solutions and proposals for improvementdevelop solutions and proposals for improvement
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The Strategic Importance of Maintenance andReliabilityThe Strategic Importance of Maintenance andReliability
Failure has far reaching effects on a firm’sFailure has far reaching effects on a firm’s
operationoperation
reputationreputation
profitabilityprofitability
customerscustomers
productproduct
employeesemployees
profitsprofits
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Tactics for Reliability and Maintenance Tactics for Reliability and Maintenance
Reliability TacticsReliability Tactics
improving individual componentsimproving individual components
providing redundancyproviding redundancy
Maintenance TacticsMaintenance Tactics
implementing preventive maintenanceimplementing preventive maintenance
increasing repair capabilitiesincreasing repair capabilities
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Centralized maintenance departmentCentralized maintenance department
Does all maintenance (PM & breakdown)Does all maintenance (PM & breakdown)
Decentralized maintenance departmentDecentralized maintenance department
Useful if different equipment used in different areas ofcompanyUseful if different equipment used in different areas ofcompany
Contract maintenanceContract maintenance
Used if little equipment or expertiseUsed if little equipment or expertise
Operator ownership approachOperator ownership approach
Organizing the Maintenance FunctionOrganizing the Maintenance Function
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Increasing Repair Capabilities:Features of A GoodMaintenance FacilityIncreasing Repair Capabilities:Features of A GoodMaintenance Facility
Well-trained personnelWell-trained personnel
Adequate resourcesAdequate resources
Ability to establish a repair plan and prioritiesAbility to establish a repair plan and priorities
Ability and authority to do material planningAbility and authority to do material planning
Ability to identify the cause of breakdownsAbility to identify the cause of breakdowns
Ability to design ways to extend MTBFAbility to design ways to extend MTBF