Tpm Sample
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The document discusses Total Productive Maintenance (TPM), which aims to achieve 100% equipment availability through eliminating equipment breakdowns, scrap, rework, and reduced productivity. TPM requires involvement from all employees and uses autonomous, preventative, and predictive maintenance strategies. The document outlines the types of maintenance strategies and provides steps for implementing TPM, including selecting a TPM area and team, developing goals, and training employees. It also discusses TPM management and metrics.
Tpm Sample
- 1. Total Productive Maintenance (TPM) Superfactory Manufacturing Excellence Series Lean Overview 5S & Visual Factory Cellular Manufacturing Jidoka Kaizen Poka Yoke & Mistake Proofing Quick Changeover & SMED Production Preparation Process (3P) Pull Manufacturing & Just In Time Standard Work Theory of Constraints Total Productive Maintenance Training Within Industry (TWI) Value Streams
- 2. Contents © 2007 Superfactory™. All Rights Reserved. Introduction Background and History Components and Implementation TPM benefits Prerequisites Types of maintenance strategies Implementing TPM TPM management Maintenance metrics Knowledge Check
- 3. Introduction © 2007 Superfactory™. All Rights Reserved. TPM is a method for continuously improving the effectiveness of production equipment and processes The key difference between TPM and other maintenance programs is that TPM requires the involvement of all people in the organization TPM aims to achieve a 100% on-demand equipment availability by eliminating: Equipment breakdowns and other unplanned downtime Scrap and rework by poor equipment performance Reduced productivity due to running at reduced speeds, idling, or stoppages requiring operator attention Equipment startup losses
- 4. Components and Implementation © 2007 Superfactory™. All Rights Reserved. TPM benefits Prerequisites Types of maintenance strategies Implementing TPM TPM management Maintenance metrics
- 5. Types of Maintenance Strategies © 2007 Superfactory™. All Rights Reserved. Breakdown Maintenance Reactive “wait until it breaks” strategy Preventative Maintenance Traditional scheduled periodic maintenance Predictive Maintenance Using monitoring equipment coupled with historical data to predict life cycle of components
- 6. Types of Maintenance Strategies © 2007 Superfactory™. All Rights Reserved. Corrective Maintenance Modification or improvement of equipment based on root cause analysis of failures Maintenance Elimination Equipment designed to eliminate all forms of maintenance
- 7. Implementing TPM © 2007 Superfactory™. All Rights Reserved. Select Facilitator Select first TPM area and team Develop goals and schedule Train team members and operators in autonomous maintenance Train maintenance technicians in preventative maintenance Train maintenance technicians in predictive maintenance
- 8. 2. Select First TPM Area and Team © 2007 Superfactory™. All Rights Reserved. First area must be able to be shut down for several days Area where downtime and quality are major problems Must have 5S program in place Team must have representatives from all shifts Team must be able to stay together after the TPM event Must include someone familiar with the technology of the equipment Include others who are unfamiliar with the equipment to add a “new set of eyes”
- 9. TPM Management © 2007 Superfactory™. All Rights Reserved. All activities involved in keeping a system’s equipment working Objective: Maintain system capability & minimize total costs Failure has far reaching effects on a firm’s operation reputation profitability customers product employees profits
- 10. Lifetime Failure Rates © 2007 Superfactory™. All Rights Reserved. Infant mortality and improper use failure “ normal” failure Wearout failure Failure rate Lifetime
- 11. Maintenance Costs Full Cost View © 2007 Superfactory™. All Rights Reserved. Maintenance Commitment Cost Optimal Total costs Full cost of breakdowns Preventive maintenance costs