Total Productive Maintenance

Thrace Sibiu 21. – 23.01.2015

Can you imagine such a situation?

05.02.2015 2
Can you imagine such a situation?

» Quality of the product is not okay

» Condition of the machine is bad
» Dirty machine and environment
» Waste is everywhere
» Rejected products and defects
» Bad and unsafe organization
» Employees are focused on firefighting-actions and problem solving
» Assignments of guilt (“The problem was your fault”)
» ….

Unplanned breakdowns lead to situations

which are out of control!!!

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Maintenance

» Unplanned breakdowns take more than twice as long as planed once

» Not regularly maintained machines lead to unstable and accident-
sensitive processes
» Most maintenance done reactive – after disruptions already happened

» BUT this can lead to…

» problems during changeover and
adjusting,
» short stops, technical disruptions
and machine breakdowns,
» degradation and lower operation
speed

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The production process as chain
The term „maintenance“ has been crucial enlarged:

Not anymore the question:

„What can I do to fix a breakdown of one element of the production?“

BUT
„What can I prophylactically do to prevent a breakdown of one element
of the production?“
„How can I already recognize a potential disturbing factor in the
process in an early stage?“
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Total Productive Maintenance
Content

1. TPM in General
» Development of TPM
» Terminology
» Principle of TPM
» Benefit
2. The 4 Pillars of TPM
» 1. Elimination of key problems
» 2. Autonomous maintenance
» 3. Planned maintenance
» 4. Maintenance prevention

3. Success Factor
1. TPM in general
Development of TPM

TPM has changed from reactive maintenance activities to …

» a preventive and corrective maintenance management

» which stretches out over the whole production system and
» thereby also integrates the employees of the production lines.

Toyota’s strength does

not come from its
healing processes! It
comes from
preventive
maintenance (TMP)”

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The Term „Total“ in TPM

Total
Machine
Efficiency

TPM
Total Total
Employee Machine
Involvement Preservation

continuous, comprehensive
waste and loss hunting
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Terminology

What is Total Productive Maintenance?

» Comprehensive productive maintenance management
» Guarantee the optimal use of the whole machine park
» Continuous improvement of the effectiveness of the machines

TPM is a lean management tool …

» whereby production employees get sensitized for the state of their
machine
» undertake defined maintenance activities by themselves
» and try to optimize their machines with the support of the
maintenance employees

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The 4 Pillars of TPM

The following 4 pillars contain the most relevant and effective TPM
elements at once:

» 5S, „Learn to see“, collaboration in the team, goals and KPI’s build
the basis for TPM.
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Principle of TPM

» not just eliminate sporadic losses (firefighter actions)

» focus on elimination of chronically, returning losses

losses
Occurs suddenly

Sporadic
losses

Chronical
losses
One has lost
the awareness Optimal
for it conditions

time 13
The six chronic sources of loss

» lived TPM-culture effects in a consequent elimination of potential

sources for losses and thereby avoid unnecessary waste
» TPM should eliminate or reduce the six chronically losses:

» Machine breakdowns identification

» Changeover and adaption time of machine losses

» Idle time and smaller disruptions and

» Machine downtime improvement

» Faulty parts of machine to

» Startup and speed losses an optimal level

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Benefits of TPM

Goal and benefits of TPM

» Methodical and permanent elimination of errors and losses

» Preventive and foresightfully avoidance of disruptions

» Avoidance of a higher workload through unplanned disruptions/ breakdowns

» Process stability through improving the machine condition

» High machine availability  optimal utilization of machines

» Continuous increase in productiveness

» Stable processes lead to stable quality

» Sensitization of employees for the machines

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Teamwork

TPM just works when all employees involved

(production AND maintenance) get integrated into the TPM-process
and actively contribute to improve the machine availability.

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2. The 4 Pillars of TPM
The 4 Pillars of TPM

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The 4 Pillars of TPM

Basis of TPM

» 5S: Cleanliness and tidiness in 5 steps

» „Learn to see“: Understanding of “value-adding”, identification of
waste and sources for losses
» Collaboration in the team: active contribution of all employees
» Goals: communicate to everybody, orientate daily actions on the goals
» KPI’s: measure goal achievement, create possibility to react quickly
onto deviations

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KPI‘s and control system

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2.1 Elimination of Key Problems
The 4 Pillars of TPM

Elimination of Key Problems

» Continuously identify sources for key problems and initiate

actions for their sustainable elimination

Tasks
1. Prioritize machines
2. Identify biggest sources for losses (eg. Error-collction-list)
3. Determine key problems
4. Analyze causes (A3/5W method, cause-effect-diagram, Pareto-Analysis)
5. Develop and execute actions
6. Execute an success control

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The 4 Pillars of TPM

Elimination of Key Problems - Examples

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2.2 Autonomous Maintenance
The 4 Pillars of TPM

Autonomous maintenance
» Maintenance department not necessary for each action
» Routinely tasks of machine maintenance can be done by production employees
» Inter-divisional cooperation of maintenance and production

7 Steps
1. Cleaning and inspection of the machine (cleaning & defect plan)
2. Elimination of defect sources
3. Development of standards (visual standards, activity plan)
4. Training of employees Together we take
care of our machines
5. Self-organized inspection and servicing through
production employees
6. Organization and optimization
7. Realize autonomous maintenance

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The 4 Pillars of TPM

Visual controls - examples

Opened during
production

Closed during
production

Depends

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2.3 Planned maintenance
The 4 Pillars of TPM

Planned maintenance
» Special tasks or actions with special requirements
» Lifetime of machines should increase, no unplanned idle times
» Inter-divisional cooperation of maintenance and production

7 Steps
1. Prioritize maintenance tasks
2. Eliminate weak points
3. Install IPS-Systems
4. Process-orientated maintenance
5. Process optimization
6. Improved maintenance: Increase efficiency, lifetime
and reliability of machine/ parts/ equipment
7. Planned maintenance program: continuous
advancement of maintenance actions

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2.4 Maintenance Prevention
 The 4 Pillars of TPM

Maintenance prevention
Maintenance prevention means that aspects like
» maintenance effort,
» accessibility and
» the ease of operation
are also considered in planning and purchasing stage of machines.

» Goal: identify and avoid errors in an early stage

» Practical experience of production and maintenance employees can
help
» Result: OEE should already increase during the starting period of the
machine (not after it)
.

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3. Success Factors
Success factors

» Own motivation: The fire you wish to light others must burn within
yourself

» Participation: TPM just works, if

» all employees involved
(production AND maintenance) get integrated in the process
» and actively contribute to improve the machine availability.

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Success factors

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