TPM

Total Productive Maintenance

 TPM - definition

• TPM can be defined as a systematic work

method aiming to develop disturbance
free processes at lowest possible cost
through the commitment of all co-workers
(LCP-Consultants)
TPM – Total Productive Maintenance

• Total Effectiveness

• Total Preventive Maintenance

• Total Commitment
 Why TPM?

• Replace routine with development

• Increased commitment from all co-workers

• Continuous improvements

• Foreseeable operations

• Improved safety and environment

 TPM Structure
Evaluation and new goals

Preparation Implementation

Safety, hygiene and environment

Early equipment management
Management’s decision Effectiveness

Effective administration
Quality maintenance
Continuous improvements
Education
Kick-off

Autonomous maintenance
Organisation and pilot
Planned maintenance
Policy and goals
Education and training
Develop a master plan
 TPM Structure
Evaluation and new goals

Preparation Implementation

Safety, hygiene and environment

Early equipment management
Management’s decision Effectiveness

Effective administration
Quality maintenance
Continuous improvements
Education
Kick-off

Autonomous maintenance
Organisation and pilot
Planned maintenance
Policy and goals
Education and training
Develop a master plan
 TPM Structure
Evaluation and new goals

Preparation Implementation

Safety, hygiene and environment

Early equipment management
Management’s decision Effectiveness

Effective administration
Quality maintenance
Continuous improvements
Education
Kick-off

Autonomous maintenance
Organisation and pilot
Planned maintenance
Policy and goals
Education and training
Develop a master plan
 TPM Structure
Evaluation and new goals

Preparation Implementation

Safety, hygiene and environment

Early equipment management
Management’s decision Effectiveness

Effective administration
Quality maintenance
Continuous improvements
Education
Kick-off

Autonomous maintenance
Organisation and pilot
Planned maintenance
Policy and goals
Education and training
Develop a master plan
The six big losses

• Failures and break-downs

• Set-up and adjustments
• Idling and minor stoppages
• Reduced speed
• Defects and rework
• Start-up losses
 Sporadic and chronic losses
Loss

Sporadic fault

Chronic faults Optimal condition

Time
 Sporadic and chronic losses
$

Chronic loss, cycle time

40s instead of 36s = 25 days

Sporadic fault
30 hrs.

weeks
 OEE calculations
Available time Planning factor =
Planning related Available time – Planning related stop time
stopps Available time
Planned
production time
Failures and Availability =
breakdowns Planned prod. time – Unplanned stop time
Unplanned

Available
operative time Set-up and Planned prod. time
stopps

adjustments
Idling and
Performance rate =
Speed loss

Net minor stoppage

operative Bought CT x items produced
time
Reduced speed Available operative time
Value
adding Defects and
Defects

operative Quality rate =

time rework
Items produced - Defects
Start-up losses Items produced

Overall Equipment Effectiveness (OEE)

= (Planning factor) x= Availability x Performance rate x Quality rate
 OEE meassures T A K K B w6 18

100%

90%

80%

70%

99, 6%
60% 97, 8%
79, 7%
50%

80, 3% 77, 6%
40%

30%

20%

10%

0%
Pl aner i ngsf aktor Ti l l gängl i ghet Anl äggni ngsutnyttj ande Kval i tet TAK
 Group activities

Autonomous maintenance group

Cross functional improvement group

Target oriented cross functional group

 Quality improvement tools

7QC/QM Identify, prioritize and analyze failures

FMEA Identify and evaluate potential weaknesses

FTA Identify causes of failures and their logic connections

PM-analysis Reduce all chronic loss to zero

 Example: ABB TAK KB

2,1% 1,2% 0,7% 0,5% 0,2%

100%
7,1%
10,0%
13,3%
90% Kvalitetsförluster
24,3% 7,3% 15,0%
27,9%
Hastighetsförluster
80% 11,0%
Stillestånd

70% 10,1% Effektivitet

15,1%
60%

50%

40% 82,2%
75,0% 77,7%

64,3%
30%
55,0%

20%

10%

0%
Januari Februari Mars April Maj
 TPM Structure
Evaluation and new goals

Preparation Implementation

Safety, hygiene and environment

Early equipment management
Management’s decision Effectiveness

Effective administration
Quality maintenance
Continuous improvements
Education
Kick-off

Autonomous maintenance
Organisation and pilot
Planned maintenance
Policy and goals
Education and training
Develop a master plan
Autonomous maintenance
 Autonomous maintenance
• Teach the operators to react on cause instead of result

• By increased kompetence and understanding the operators may:

– Eliminate minor stoppages
– Prevent break-downs
– Secure implemented improvements
– Improve quality, safety, and environment

• In the long run operators start to perform maintenance tasks

• Daliy inspections replaces repair and low frequent controls

• Implemented through seven well-defined steps

• Takes long time to implement, often years

 The seven-step ladder

Description Competence
Factory focusing step. Repair skills
7. Autonomous maintenance
From maintenance to
control.
6. Organize the work environment Understands the
relation between
Focuses the operators. maintenance and
They learn advanced
5. Autonomous inspection product quality
inspection and
maintenance techniques 4. General inspection training Understands the
functions and structure
Equipment of the machines
focusing step. 3. Standards for cleaning and lubrication
Secures the basic
Can find defects and
condition of the 2. Counter meassures at the problem source understand the principles for
equipment
improvements of the
1. Basic cleaning and order equipment
 TPM Structure
Evaluation and new goals

Preparation Implementation

Safety, hygiene and environment

Early equipment management
Management’s decision Effectiveness

Effective administration
Quality maintenance
Continuous improvements
Education
Kick-off

Autonomous maintenance
Organisation and pilot
Planned maintenance
Policy and goals
Education and training
Develop a master plan
 Planned maintenance
Activities for improved OEE
maintenance effectiveness

Maintenance planning
Activities for improved

Condition Based Maintenance

Improvement Maintenance

Information feedback
Corrective Maintenance

Preventive Maintenance

Restoring Maintenance
Maintenance control

Spare part control

Economy control

Implementation of planned maintenance leads to:

-Increased MTBF and MTBM
-Decreased MTTR, MWT and M
-Closer to 0-faults, 0-stops and 0-accidents
 TPM Structure
Evaluation and new goals

Preparation Implementation

Safety, hygiene and environment

Early equipment management
Management’s decision Effectiveness

Effective administration
Quality maintenance
Continuous improvements
Education
Kick-off

Autonomous maintenance
Organisation and pilot
Planned maintenance
Policy and goals
Education and training
Develop a master plan
 TPM Structure
Evaluation and new goals

Preparation Implementation

Safety, hygiene and environment

Early equipment management
Management’s decision Effectiveness

Effective administration
Quality maintenance
Continuous improvements
Education
Kick-off

Autonomous maintenance
Organisation and pilot
Planned maintenance
Policy and goals
Education and training
Develop a master plan
 Early equipment management
Goal and
Basic properties LCC
requirements
The process has to goals:
•To reach stable, full speed production at start-up. Acquisition process
•To, as far as possible, meet the detailed
Project Structure and process thinking
requirements for the equipment.

Experience development Early detection of

MP-design problems

The included activities are aiming for new equipment to be:

•Reliable and producing non defective products.
•Easy to mend and set up, and fast to start after set-up changes.
•Easy to maintain, and fast to localize faults and repair.
•Easy to clean, lubricate and inspect.
•Resource efficient and safe.
 TPM Structure
Evaluation and new goals

Preparation Implementation

Safety, hygiene and environment

Early equipment management
Management’s decision Effectiveness

Effective administration
Quality maintenance
Continuous improvements
Education
Kick-off

Autonomous maintenance
Organisation and pilot
Planned maintenance
Policy and goals
Education and training
Develop a master plan
Quality maintenance
 Quality maintenance in 17 steps
1 Control of quality standard and quality parameters
2 Localizing origin of quality defects
Phaze 1

3 Choice of pilot equipment and defect for implementation of quality maintenance

4 Evaluate function, operating state and method for set-up change of equipment
5 Examine and restore the state of the equipment
6 Perform PM-analysis
Phaze 2

7 Eliminate all defect creating factors

8 Define prefered state and optimize operating conditions and method for set-up
change
9 Detect defects
10 Restore or improve
Phaze 3

11 Evaluate standard values and which components to inspect

12 Determine the valid state for production of non-defective products
13 Reduce the number of inspection points
14 Define standard values for inspection points
Phaze 4

15 Make a draft for a quality matrix

16 Discuss the content of the inspection standard
17 Evaluate and, if needed, change the standards and inspection points
through trend analysis
 TPM Structure
Evaluation and new goals

Preparation Implementation

Safety, hygiene and environment

Early equipment management
Effectiveness

Effective administration
Management’s decision

Quality maintenance
Continuous improvements
Education
Kick-off

Autonomous maintenance
Organisation and pilot
Planned maintenance
Policy and goals
Education and training
Develop a master plan
 Effective administration
• The aim is to create effective administrative processes through:
– Reduce loss and waste
– Develop a work process that can handle change

• The goal is that all efforts aim at value creating tasks from the
customers point of view (external and internal)

• Resembles ”Autonomous maintenance” but in a different context

• Adds credibility to the organization by using the same tools as in the

production

• Implemented through seven steps

 TPM Structure
Evaluation and new goals

Preparation Implementation

Safety, hygiene and environment

Early equipment management
Management’s decision Effectiveness

Effective administration
Quality maintenance
Continuous improvements
Education
Kick-off

Autonomous maintenance
Organisation and pilot
Planned maintenance
Policy and goals
Education and training
Develop a master plan
 TPM Structure
Evaluation and new goals

Preparation Implementation

Safety, hygiene and environment

Early equipment management
Management’s decision Effectiveness

Effective administration
Quality maintenance
Continuous improvements
Education
Kick-off

Autonomous maintenance
Organisation and pilot
Planned maintenance
Policy and goals
Education and training
Develop a master plan
 Results of TPM at Volvo
Productivity Breakdowns reduced with 90%

OEE increased from 50% to 90%

MTBF increased from 30 minutes to 8 hours

Quality Scrap reduced with 90%

Cost of quality control reduced with 67%

Customer complaints reduced with 75%

Costs Production cost reduced with 30%

Delivery precision Capital bound in WIP and finished goods decreased with 50%

Fulfillment actual/desired delivery time increased to 90%

Delivery precision actual/promised time increased to 100%

Safety Accidents resulting in personal injuries reduced to 0

Accidents resulting in pollution reduced to 0

Commitment Ten times as many suggested improvements

Time for education and training increased with 100%