Total Productive Maintenance

and Maintenance Management http://www.managementsupport.com

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Outline

       What is Total Productive Maintenance Origins of TPM TPM Principles Components of TPM       Autonomous Maintenance Planned Maintenance Equipment & Process Improvement Early Management of New Equipment Process Quality Management TPM in the Office Implementing TPM TPM Benefits Maintenance Management & Strategy 2

What is TPM

    A company-wide team-based effort to build quality into equipment and to improve overall equipment effectiveness Total   all employees are involved it aims to eliminate all accidents, defects and breakdowns Productive  actions are performed while production goes on  troubles for production are minimized Maintenance   keep in good condition repair, clean, lubricate 3

Autonomous Maintenance

 7 steps are implemented to progressively increase operators knowledge, participation and responsibility for their equipment  1. Perform initial cleaning and inspection   2. Countermeasures for the causes and effects of dirt and dust 3. Establish cleaning and lubrication standards    4. Conduct general inspection training 5. Carry out equipment inspection checks 6. Workplace management and control  7. Continuous improvement 4

Early Management of New Equipment

  Objective: establish systems to shorten  new product or equipment development  start-up, commissioning and stabilization time for quality and efficiency New equipment needs to be:      easy to operate easy to clean easy to maintain and reliable have quick set-up times operate at the lowest life cycle cost 5

7: Develop Equipment Management Program

   The tools of Total Quality Management and Continuous Improvement are applied to the management and improvement of equipment Form project teams Select model equipment    identify equipment problems analyze equipment problems develop solutions and proposals for improvement 6

The Strategic Importance of Maintenance and Reliability

 Failure has far reaching effects on a firm’s  operation  reputation      profitability customers product employees profits 7

Tactics for Reliability and Maintenance

  Reliability Tactics  improving individual components  providing redundancy Maintenance Tactics   implementing preventive maintenance increasing repair capabilities 8

Organizing the Maintenance Function

    Centralized maintenance department  Does all maintenance (PM & breakdown) Decentralized maintenance department  Useful if different equipment used in different areas of company Contract maintenance  Used if little equipment or expertise Operator ownership approach 9

Increasing Repair Capabilities:Features of A Good Maintenance Facility

      Well-trained personnel Adequate resources Ability to establish a repair plan and priorities Ability and authority to do material planning Ability to identify the cause of breakdowns Ability to design ways to extend MTBF 10