Total Productive Maintenance

TPM - TOTAL PRODUCTIVE
MAINTENANCE

POWERPOINT TEMPLATE

AGENDA 1. Quotes
2. What is Total Productive

Maintenance?
3. Why TPM?
4. Benefits of TPM
5. 8 Pillars of TPM
6. Implementation in 7 Steps
7. Key Figures of TPM
8. Objectives of TPM
9. Losses in the Production Process
10. Implementation of TPM
11. Roles and Responsibilities
12. Sustainment of the TPM Concept

Our economic system measures productivity
in a way, that allocates more attention to the
good things, which we produce, than to the
bad things. But every production process
creates waste.

Albert A. Gore Jr.
(Former Vice President of the USA and Nobel Peace Prize Laureate)

Nobody can hold back changes in productivity in the
long run, as the market demands for them, inexorably.

Bill Gates (Founder of Microsoft)

Another flaw in the human character is that everybody
wants to build and nobody wants to do the maintenance.

Kurt Vonnegut (US-American Writer)

The nicest thing about standards is that
there are so many of them to choose from.

Ken Olsen (US-American Engineer & Founder of DEC)

DEFINITION

What is Total Productive Maintenance?

Concept with the aim to maximize the productivity
of facilities by transferring the responsibility for regular
maintenance to employees

Productivity-oriented mixture of preventive and
status-oriented maintenance measures, supplemented
by a process of continuous improvement of facilities

Consists of 8 pillars, each containing approaches
to eliminate losses and waste

DEFINITION

What is Total Productive Maintenance?

TOTAL PRODUCTIVE MAINTENANCE

 Refers to all departments,  Maximization of the efficiency  Improvement of the efficiency of
facilities and processes of the production system facilities and plant

 Participation of all employees  Production of goods and  Continuous sustainment and
 Aim to eliminate all defects, services that exceed the customers’ improvement of the overall
expectations condition of plant and machinery
breakdowns, accidents etc.
 Minimization of obstacles within  Concerns whole life cycle of the
the production process production system

TYPES OF MAINTENANCE

Simple Approach

MAINTENANCE

PREVENTIVE CORRECTIVE

CALENDAR BASED CONDITION BASED PLANNED UNPLANNED

WHY TPM? Thus, cost disadvantages are
balanced; productivity and
Initial Situation competitiveness are raised

Profitable production at high-cost-
site Germany only possible through
automation of production facilities

Separation of production and Proceeding automation generates
maintenance has negative impact increasing number of error sources,
on the effective use of production which counteract productivity
facilities
Complex requirements concerning
High demands on productivity availability and rebuilding of facility
and flexibility of facility systems, systems are necessary
to secure customer satisfaction
and competitiveness

BENEFITS OF TPM INDIRECT BENEFITS

DIRECT BENEFITS  Increase of employee motivation and satisfaction
 Varied and challenging work
 Reduction of defects, interruptions and waste  Sustainment of a clean, structured, attractive work place
 Increase of productivity and running times  Reaching goals in team work
 Lower costs for maintenance and production  Exchange of knowledge and experience
 Improved control of maintenance costs  Higher qualification through education and trainings
 Less time for set-up and adjustment of facilities  Maintenance measures can be exercised by the
 Machines can be operated and maintained
operator himself
more easily  Employee feels responsible for avoiding mistakes
 Improvement of standards for job safety and
at “his” machine
process reliability  More participation and voice for employees
 Higher customer satisfaction
 Improved delivery results

8 PILLARS OF TPM Continuous
Improvement
Design
Autonomous
TOTAL Maintenance
PRODUCTIVE MAINTENANCE
Preventive
5S Maintenance

Trainings
and Education

Start-up Monitoring

Quality Management

TPM in Administration

Safety and Health at Work,
Environment Protection

8 PILLARS OF TPM Continuous Improvement
Autonomous Maintenance
Design Preventive Maintenance

Total Productive Maintenance Trainings and Education
Start-up Monitoring
5S Quality Management
TPM in Administration

Safety and Health at Work,
Environment Protection

Continuous Improvement 8 PILLARS OF TPM
Autonomous Maintenance
Design
Preventive Maintenance
Trainings and Education Total Productive Maintenance

Start-up Monitoring 5S
Quality Management

TPM in Administration
Safety and Health at Work,

Environment Protection

8 PILLARS OF TPM Continuous Improvement
Autonomous Maintenance
1. Continuous Improvement Preventive Maintenance
 Applied elimination of major losses Trainings and Education
Start-up Monitoring
2. Autonomous Maintenance Quality Management
 Operator executes inspections, cleanings and TPM in Administration
Safety and Health at Work,
maintenance independently Environment Protection

3. Preventive Maintenance
 Undisturbed machines and facilities produce faultless

goods for total customer satisfaction
 Educated maintenance staff instructs machine operator

to improve the maintenance of their equipment
 Documentation of deficits with the help of scarcity cards

8 PILLARS OF TPM Continuous Improvement
Autonomous Maintenance
4. Trainings and Education Preventive Maintenance
 Tailored qualification of employees to improve their Trainings and Education
Start-up Monitoring
abilities to operate and maintain Quality Management
 Aim is the multi-qualified worker, who fulfills all TPM in Administration
Safety and Health at Work,
required tasks effectively and independently Environment Protection
 Necessary employee competencies:

1. Method competency (e.g. organizational skills)
2. Subject competency (e.g. machine handling, organization of spare parts)
3. Social competency (e.g. capacity for teamwork, motivation)

5. Start-up Monitoring
 Realization of a vertical starting curve at new products

and facilities

8 PILLARS OF TPM Continuous Improvement
Autonomous Maintenance
6. Quality Management Preventive Maintenance
 “Zero Defects” target concerning products and facilities Trainings and Education
 Customer satisfaction through highest quality and Start-up Monitoring
Quality Management
accurate manufactures TPM in Administration
 Systematic elimination of facility parts, which have Safety and Health at Work,
Environment Protection
negative impact on productivity

7. TPM in Administration
 Elimination of losses and waste in non-productive sections

8. Safety and Health at Work, Environment Protection
 Zero accidents, zero pollution, zero illnesses

8 PILLARS OF TPM FIRST CLASS RESULTS

Design Start-up Monitoring

Continuous Improvement TPM Quality Management
Autonomous Maintenance
Preventive Maintenance TPM in Administration
Trainings and Education
Safety, Health, Environment Protection

5S BASE

IMPLEMENTATION OF THE PILLARS IN 7 STEPS

Step 7 Full autonomous maintenance
Step 6 Standards through visualization
Step 5 Conduction of autonomous inspections

Step 4 Conduction of general inspections
Step 3 Draw up cleaning and lubrication standards

Step 2

Elimination of problem sources and inaccessible areas

Step 1

Initial cleaning of machines, equipment and surroundings

IMPLEMENTATION OF THE PILLARS IN 7 STEPS

7 AUTONOMOUS MAINTENANCE Target achievement through
personal responsibility of employees

6 STANDARDS FOR PROCESS Overall standards for logistics,
SECURITY data collection, process quality etc.

5 INDEPENDENT INSPECTION Maintenance by operators with the
help of checklists and inspection plans

4 TRAINING FOR INDEPENDENT Transfer of knowledge and know-how
INSPECTION about construction of machines

3 PRELIMINARY STANDARDS Standards for cleaning, lubrication and
FOR CLEANING AND INSPECTION order with checklists and inspection plans

2 ELIMINATION OF PROBLEM Elimination of inaccessible areas,
SOURCES pollution, leaks etc.

1 INITIAL CLEANING AND INSPECTION Thorough cleaning and inspection of
machines, facilities and work environment

KEY FIGURES OF TPM

P Q C D SM

Productivity QUALITY COSTS DELIVERY SAFETY MULTITASK

Labor Number of Reduction Stock quantity, Number of Development
productivity, process errors, of costs for inventory accidents, of multi-capable
value creation, maintenance, turnover, machine
reduction of defects, servicing and breakdowns, and flexible
interruptions customer delivery results cases of illness employees
complaints energy

QUALITATIVE OBJECTIVES

GOAL 1

Improvement of machine availability

GOAL 8 GOAL 2

Maximization of facility efficiency Establish maintenance throughout
total equipment life cycle
GOAL 7
GOAL 3
Increase of worker satisfaction
Improvement of
GOAL 6 corporate culture and image

Improvement of GOAL 4
cross-functional teamwork
Optimization of
business performance

GOAL 5

Improvement of working environment

QUANTITATIVE OBJECTIVES

GOAL 7 GOAL 1

Increase number Zero mistakes, zero accidents,
of training sessions zero complaints

GOAL 6 GOAL 2

MTBR: increase mean time Zero defects, zero breakdowns,
between repairs zero damages, zero waste

GOAL 5 GOAL 3

MTBF: increase mean time Cost reductions by
between failures energy savings and maintenance

ZIEL 4

Reduction of idle times

LOSSES IN PRODUCTION

The TPM concept deals with the search for losses and wastages
within the production process with the aim of zero defects, zero
blackouts, zero quality losses, zero accidents etc.

PROBLEM: Minor defects at machines are usually not recognized,
but are causing the main part of machine breakdowns.

EXAMPLES: DELAMINATION, CORROSION
CONTAMINATION, DUST DEFORMATION, VIBRATION
DETERIORATION, EROSION INCORRECT TEMPERATURE
LEAKS, CRACKS

LOSSES IN PRODUCTION

6 Major Losses

1 Breakdowns Machine breakdowns over 10
minutes, more than once a month
AVAILABILITY 2 Setups and
Adjustments Times for set-up and adjustment
over 10 minutes
3 Reduced Speed
Suboptimal cycle times
OVERALL EQUIPMENT PERFORMANCE and machine pulsing
EFFECTIVENESS
Stops and Stoppages and idle times
4 Idle Times over 10 minutes

QUALITY 5 Defects and Rework rate higher than 0,1%
Rework
Profit cuts by startup difficulties
6 Startup and
Yield Loss

IMPLEMENTATION OF TPM

Common Problems during the Introduction of TPM

Different objectives of Insufficient allocation Poor reception and
management and employees of essential resources application of new knowledge

Lacking support Low sense of responsibility
by management levels
Job worries of employees
Lacking understanding
of TPM benefits Corporate strategy not in
line with TPM objectives
Low consideration of Lacking or limited
individual requirements commitment of employees

IMPLEMENTATION OF TPM

Success Criteria

WORK GROUPS COOPERATION SUPPORT APPLICATION

Common decision making Involvement of all concerned in Support and understanding TPM activities become daily
of all involved employees planning and realizing measures of maintenance measures routine for every employee

IMPLEMENTATION OF TPM

5 Phases Approach

PHASE 1 PHASE 2 PHASE 3 PHASE 4 PHASE 5

Project guideline Data collection, Develop action Implementation of Inter-divisional
with analysis and identification of deficits plans and scenarios the TPM concept distribution of
the TPM concept
objectives and potentials

IMPLEMENTATION OF TPM PHASE 2

5 Phases Approach  Analysis of basic data and processes
 Identification of weak points
PHASE 1  Definition of fields of action
 Evaluation of potentials to be unlocked
 Determination of productivity
targets of facility systems

 Definition of the project scale

IMPLEMENTATION OF TPM

5 Phases Approach

PHASE 3 PHASE 4 PHASE 5

 Conceptual definition  Institutionalization of the  Extension of the TPM concept
of all TPM modules overall concept by continuous to further production areas
improvement of facilities
 Measures to optimize  Optimization of the
the usage time  Protection of the efficiency cost-benefit ratio
of the process
 Scenarios for different areas  Area wide intersection of the
(technics, organization, staff) TPM concept by measures
related to causes and effects
 Content facility management

IMPLEMENTATION OF TPM

12 Steps Approach

PREPARATION 1. Announcement to introduce TPM
START 2. Introductory education campaign for the workforce
3. Promotion of TPM by special committees
IMPLEMENTATION 4. Establishment of basic TPM policies and goals
STABILIZATION 5. Preparation and formulation of a master plan

6. Invitation of customers, affiliated companies and subcontractors

7. Development of an equipment management program
8. Development of a planned maintenance program
9. Development of an autonomous maintenance program
10. Increase skills of production and maintenance staff
11. Development of equipment management program

12. Raise TPM levels after perfect implementation

ROLES IN THE TPM PROCESS

OPERATOR

 Maintains basic condition, e.g. cleaning and lubrication
 Maintains proper condition and standards for equipment usage
 Eliminates deterioration
 Basic skills in changeover, set-up and adjustment

MAINTENANCE

 Technical support for autonomous maintenance by operators
 Check-ups, inspections and overhauls
 Improvement of the equipment to error-free function
 Improvement of technical maintenance skills for check-ups and inspections

RESPONSIBILITIES IN THE TPM PROCESS

ADVISORY

 Guide and challenge TPM implementation
 Development processes to measure main losses
 Plant-wide introduction of TPM standards with the help of a master plan
 Monitoring and evaluation of TPM measures; assistance for work groups

WORK GROUP FACILITY IMPROVEMENT

 Investigation and reduction of 6 main losses
 Transfer of routine maintenance skills to operators
 Introduction of standards for routine maintenance and inspections by operators
 Organization of the work area for more effective and efficient maintenance

SUSTAINMENT OF TPM

 Management exemplifies TPM to workforce
 Employment of qualified personnel
 Continuous striving for success
 Active instruction to implement TPM
 Celebrate success
 Gratifications and appreciation
 Constant improvement of

Overall Equipment Effectiveness (OEE)
 Advancement of TPM concept (e.g. Lean approach)