TPM “Basics” Decision Tree TPM Pilot Flowchart

Starting TPM 1. Management Commitment

to Pursue TPM

1. Do We Have a PM 2. Pilot Areas Readiness

Develop a PM Program
Program? Assessment
SELECTING...
2. Evaluate the Effectiveness 2A. Review Potential
Of the PM Program Pilot Areas

High
Constraint High Added Capacity Quality
3. Is It Effective - <20% Reactive Implement Effective Maintenance
Equipment? Downtime? Needed? Problems?
Work Performed? PM Procedures Cost?

4. Review Maintenance Stores 2B. Select Pilot Area

- Operations/Manufacturing
- Maintenance
2C. Determine Natural - Process Improvement
Develop Effective Work Group - Engineering
5. Are Stores Effective -
Stores Procedures - Quality
>95% Service Level? - Other Support
2D. Identify Readiness:
6. Review Work Order System

Willing Management Willing Early Results

7. Are Work Orders Fully Implement an Effective Workforce? Possible?
& Supervision
Utilized (100% Coverage)? Work Order System

2E. Identify Basics In Place

8. Review Planning & Scheduling or Needed:

9. Is Planning & Implement Effective Maintenance Trained Trained Performance Equipment

Scheduling Effective - Maintenance Planning & Basics? Operators? Maintainers? Tracking? Management?
>80% Weekly Scheduling
- CMMS
- Preventive Maintenance
10. Investigate Computerization - Lubrication
Of Work Order System - Spare Parts 2F. Determine Schedules:
- Work Requests/Orders
10a. Establish
Does the Work Order 10b. Is the Manual
a Manual Meetings Maintenance
System Require System Shift/Days Training Time On-Job Training
Maintenance Shutdowns
Computerization? Effective?
System

10c. Evaluate Work 2G. Develop Preliminary

11. Purchase & Implement Plan & Schedule
Order Process.
A CMMS (EMIS)
DEVELOPING... 3. Pilot Area Preparation
12. Is the CMMS Identify &
Usage Effective? Correct Problems 3A. Work Group TPM
Orientation:

13. Investigate Operator Involvement

To Selecting & Developing TPM Why Area Was Opportunities
In Pilot Area What Is TPM?
Pilot Area (Step 1) Selected

Are There Activities the 3B. Form Area TPM

Re-evaluate the
Operators Could Be Involved In? Design Team
Activities
3C. Design Team
- Operator Cleaning & Inspecting TPM Education
14. Identify the Activities - Work Requests
- Visual Systems 3D. Identify TPM Starting
Points:
Train & Certify the
15. Are the Operators Certified to Operators to Perform Tracking,
Perform the Activities? Enhance The Operator
the Activities Work Request Reporting, Visual Systems
“Maintenance Cleaning &
System Analyzing For TPM
Basics” Inspecting Performance
To Selecting &
16. Begin Operator Involvement Developing TPM Pilot
3E. Develop Detailed
Areas (Step 6)
Plan & Schedule

17. Is Predictive Maintenance Begin Predictive Maintenance

Being Performed? 3F. Conduct Focused Training
- Life Cycle Costing
-RCM
18. Investigate Reliability Engineering 4. Apply TPM Learning
-FEMA
- Early Equipment Management & Design
4A. Monitor Performance:
Is Reliability Data Used for Begin Using Reliability
All Equipment Making Decisions? Engineering Techniques Refocus
Refine & Develop
Starting Point
- Total Cost Analysis
19. Investigate Financial EXPANDING... 5. Improved Equipment
Optimization - All Potential Costs Related to Equipment Performance
Decisions Are Calculated

6. Enhance TPM Pilot Initiatives:

20. Are the Tools & Data Available Develop the Tools & Data
for Financial Optimization?
Operator Performed Autonomous Predictive
Other
Re-evaluate Previous Maintenance Maintenance Maintenance
21. Use Financial Optimization Decisions

7. Improved Equipment
Performance
22. Are We Successful Investigate Problems
With TPM? & Correct
8. Expand TPM? Continue or Stop

23. Strive for Continuous Improvement

Step 2: “Pilots Area Readiness
www.RedVector.com Assessment”