Transcript Document

TOTAL PRODUCTIVE
MAINTENANCE
‘Failure prevention’
LEARNING OUTCOMES
…to understand the concept of
Total Productive Maintenance (TPM)
…to understand the impact of failure for
a fashion operation
DEFINITION OF TPM
“Total Productive Maintenance recognises
the importance of reliability, maintenance
and economic efficiency
in plant design”
“Accepting that sometimes failure will occur
is not the same as ignoring it”
(Slack et al, 2007)
THE FIVE GOALS OF TPM
1.
2.
3.
4.
Improve equipment effectiveness
Achieve autonomous maintenance
Plan maintenance
Train all staff in relevant maintenance
skills
5. Achieve early equipment management
THE GOAL OF TPM
1. To minimise waste in a fast changing
economical environment
2. To increase production efficiency without
reducing product quality
3. To reduce cost
4. To reduce production time
5. To ensure non defective goods to customer
FAILURE PLANNING
Discover
Act
Learn
Plan
The facts - what has happened?
The consequences
Inform, contain and follow up
Find the root cause
Prevent it happening again
Failure analysis - possibilities
Recovery planning - procedures
TYPES OF FAILURE
Supply
failures
Failures inside
the operation
Design failures
Facilities failures
Staff failures
Environmental disruption
Customer
failures
FAILURE DETECTION
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In-process checks
Machine-diagnostic checks
Point-of-departure interviews
FAILURE ANALYSIS
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Accident investigation
Product liability
Complaint analysis
Critical incident analysis
Failure mode-and-effect analysis
Fault-tree analysis
FAILURE MEASUREMENTS
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Failure Rate (FR)
Reliability
Availability
FAILURE ANALYSIS AND
RECOVERY PLANNING
Failure detection and analysis
Finding out what is going wrong
and why
Improving system reliability
Recovery
Stopping things from going wrong
Coping when things do go wrong
BENEFITS WITH TPM
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Improved system reliability
Increases productivity (by 1.5 to 2 times)
Resolves customer complaints
Reduces manufacturing cost (by 30%)
Satisfy customer needs (by 100%)
• Right quantity, time, quality
Reduce accidents
Follow pollution and control measures
TPM vs. TQM
SIMILARITIES
• Total commitment
• Employee empowerment
• A holistic approach to improvement
DIFFERENCES
Category
TQM
TPM
Object
Quality
Output and effects
Equipment
Input and cause
Method
Systematisation
Software oriented
Participation
Hardware oriented
Goal
Product and process
quality
Elimination of
losses and wastes