Transcript TPM - Lean CEO

Total Productive Maintenance
and Maintenance Management
Lean Manufacturing Series
© 2009 Factory Strategies Group LLC. All rights reserved.
Outline
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What is Total Productive Maintenance
Origins of TPM
TPM Principles
Components of TPM
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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
© 2009 Factory Strategies Group LLC. All rights reserved.
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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
© 2009 Factory Strategies Group LLC. All rights reserved.
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Autonomous Maintenance
• 7 steps are implemented to progressively increase
operators knowledge, participation and responsibility
for their equipment
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Perform initial cleaning and inspection
Countermeasures for the causes and effects of dirt and dust
Establish cleaning and lubrication standards
Conduct general inspection training
Carry out equipment inspection checks
Workplace management and control
Continuous improvement
© 2009 Factory Strategies Group LLC. All rights reserved.
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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:
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easy to operate
easy to clean
easy to maintain and reliable
have quick set-up times
operate at the lowest life cycle cost
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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
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The Strategic Importance of Maintenance and
Reliability
• Failure has far reaching effects on a firm’s
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operation
reputation
profitability
customers
product
employees
profits
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Tactics for
Reliability and Maintenance
• Reliability Tactics
▫ improving individual components
▫ providing redundancy
• Maintenance Tactics
▫ implementing preventive maintenance
▫ increasing repair capabilities
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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
© 2009 Factory Strategies Group LLC. All rights reserved.
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Increasing Repair Capabilities:Features of A
Good Maintenance Facility
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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
© 2009 Factory Strategies Group LLC. All rights reserved.
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