TPM-Total Productive Maintenance

 

What is Total Productive Maintenance?

TPM is a method for continuously improving the effectiveness of production equipment and processes

TPM is a plant improvement methodology which enables continuous and rapid improvement of the manufacturing process through use of employee involvement, employee empowerment, and closed-loop measurement of results

How is this Accomplished?

» By improving On Demand availability of the equipment, through improved maintenance

How is this Different from Other Maintenance Programs?

• Primary difference between TPM and most maintenance programs is the involvement of the machine operator as a front line defense against…

–Equipment breakdowns and other unplanned downtime

– Scrap and rework caused by poor equipment performance

–Reduced productivity due to running at reduced speeds, idling, or stoppages requiring operator attention

–Equipment startup losses

Breakdown of TPM

TOTAL = All encompassing by maintenance and production individuals working together

PRODUCTIVE = Production goods and services that meet or exceed customers’ expectations

MAINTENANCE = Keeping equipment and plant in as good as or better than the original conditions at all times

 

Brief History of TPM

» Productive maintenance (PM) originated in the U.S. in late 1940’s & early 1950’s Japanese companies modified and enhanced it to fit the Japanese industrial environment. (Japanese auto manufacturers studied these methods at this time)

»First true TPM initiative developed by Nippondenso in the late 1960’s, a Japanese auto components manufacturer

»Seiichi Nakajima – head of JIPM, one of the earliest proponents, known as the Father of TPM 

» First true TPM in the United States developed by Kodak’s Tennessee Eastman facility in 1987

TPM - Evolution

-Breakdown maintenance

-Preventive maintenance (PM)

-Productive maintenance

- Total productive maintenance

 

Goals of TPM

1. Aims at getting the most effective use of equipment

2. Builds a comprehensive PM system

3. Brings together people from all departments concerned with equipment

4.Requires the support and cooperation of everyone from top managers down

5. Promotes and implements PM activities based on autonomous small group activities.

6.Maintaining Equipment for life

7.Encouraging input from all employees

8.Using teams for continuous improvement

Three Principles of Prevention

•Maintenance of normal conditions

•Early discovery of abnormalities

•Prompt response

TPM 8 PILLARS

Kick off TPM 

Launching TPM- Preparatory Stage

•Announce top management’s decision to introduce TPM

• Launch an educational campaign to introduce TPM

•Create an organizational structure to promote TPM

•Establish basic policies

•Form a master plan for implementing TPM

 

 

Launching TPM- TPM Implementation

• Improve the effectiveness of each critical piece of equipment

•Set up and implement autonomous maintenance

•Establish a planned maintenance system in the maintenance department

•Provide training to improve operator and maintenance skills

•Develop an early equipment management program

Launching TPM- Stabilization

•Perfect TPM implementation and raise TPM levels

 

Eliminating Equipment Losses

 

Improvement Goals for Chronic Losses

 

TPM BENIFITS

» Improved equipment eliminates the root cause of defects

» Defects are prevented through planned maintenance

» Preventive maintenance costs are reduced as equipment operators conduct autonomous                          maintenance

» Improved equipment designs ensure that new equipment naturally produces fewer defects

» Simplified products designs and a redesigned process produce with few defects

» Engineers, technicians and managers are trained in maintenance and quality

TPM - Benefits

(Japanese TPM Prize winners during 1982-1984)

•Equipment failures reduced from 1,000/month to

20 /month

•Quality defects reduced from 1.0% to 0.1%

•Warranty claims reduced by 25%

•Maintenance costs reduced by 30%

•WIP decreased by 50%

• Productivity improved by 50%. (Patterson & Fredendall, 1995)

TPM – Success stories

•USPS Albany, New York: annual save of $86,000; could save $4.5 million if applied nationwide

•Yamato Kogyo Corp., Japan:

- productivity up by 130%,

- accidents cut by 90%,

-defects reduced by 95%,

- employee suggestion rate increased by over 300%

 

Summary

»TPM is a method for continuously improving the effectiveness of production equipment and processes

»By improving On Demand availability of the equipment, through improved maintenance

» With a primary focus on involving machine operators in routine maintenance

» And making that maintenance easily seen, easily done, and effective