PQT - Total Productive Maintenance
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This document provides an overview of Total Productive Maintenance (TPM). TPM aims to eliminate losses like equipment downtime, defects, and accidents by involving machine operators in preventative maintenance. Its objectives are to create a safer work environment, improve quality, reliability, and financial performance. TPM measures effectiveness using Overall Equipment Effectiveness (OEE) and addresses six major losses: availability, performance, and quality losses. It works by establishing pillars like autonomous, planned, and quality maintenance.
PQT - Total Productive Maintenance
- 1. PQT - Total Productive Maintenance
- 2. TPM overview 2 T P M Total Productive Maintenance What’s TPM How TPM works Concept Zero TPM Targets Why TPM Objectives of TPM
- 3. What’sT P M • TPM wasdeveloped in the 1970's as amethodof involving machineoperators in the preventive maintenanceof their machines – a reaction to increasing specialization and centralization of the maintenance function that had createddivision-of-labor barriers between operators and the maintenance of their machines and equipment. – Also creating a sense of ownership in workers with Autonomous Maintenance 3
- 4. Objectives ofT P M • Theoverriding objective ofTPMis the elimination ofLOSSES. Losses, or waste, includes equipment downtime, defects, scrap, accidents, wasted energy, and laborinefficiency. • TPM was introduced to achieve some of the following important objectives: – Safer working environment, Job security – Producing goods with improved quality and machinereliability – Improvedfinancial performance – Producea low batch quantity at the earliest possible time. – Goods send to the customers must benon defective 4
- 5. Why T P M 5 Before 1 Severe problem occured, there were 300 minor and 29 major problems to handle. Source: Kaizen Institute, Frankfurt Heinrich‘s Law TPM is a tool which addresses potential signs of machine break-downs and is therefore an important instrument to prevent total machine crashes. 1 29 300 Severe problem Minor problems Major problems
- 6. Concept ZERO • Thegoal of TPM isto driveallwastetozero: ZeroAccidents,Zero Defects,ZeroBreakdowns. • TheConcept of Zero is built upon Poka-Yoke, in the design of the process to make it impossible to makeand pass on defects. • Poka-Yoke concepts are also commonlyapplied to equipment to prevent breakdowns. • Poka (Mistakes), Yokeru(Avoid) orMistake Proofing (Japanese Term) 6
- 7. Performance Measure and 6 Losses • Overall Equipment Effectiveness (OEE)is the performance measureof TPM. • Thus factors affecting OEE/ TPM: • Availability • Performance • Quality – Associated 6 big losses are: • Availability Losses: Breakdown losses causedby the equipment; Set-up and adjustment losses • Performance Losses: Minor stoppage losses; Speed losses • Quality Losses: Quality defect and rework losses; Yield losses 7
- 10. Types ofMaintenance • BreakdownMaintenance:Thisoccurs when equipment failsbut doesnot affect production or operationor extracostsother than repairs • PreventiveMaintenance:A dailymaintenancedesignedto maintainequipment againstfailingand alsoimprovedhealthcondition – PeriodicMaintenance:Atimebasedmaintenance – PredictiveMaintenance:Maintenancebased on condition monitoringby employingsurveillancesystem • CorrectiveMaintenance:Redesigningequipmentwith weaknessto improve reliability • MaintenancePrevention:Thisindicatesdesignof new machineby Cross functional teams afterthorough study on weaknessof current machines 10
- 11. TPM Targets 11 P roduction: Obtain Minimum80% OPE (Overall Process Effectiveness) Obtain Minimum90% OEE(Overall Equipment Effectiveness) Runthe machineseven duringlunch.(Lunch is for operators and not for machines!) Quality: Operate in a manner,so that thereareno customer complaints. C osts: Reduce themanufacturingcost by 30%. D elivery: Achieve100%success indelivering the goods as requiredby the customer. Safety: Maintain a accident freeenvironment. M aintenance: Develop Multi-skilled and flexible workers. And Cross functionalteams