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) “An approach to maintenance management that adopts a similar holistic approach to TQM.”

THE FIVE GOALS OF TPM Improve equipment effectiveness Achieve autonomous maintenance Plan maintenance Train all staff in relevant maintenance skills Achieve early equipment management

THE GOAL OF TPM To minimise waste in a fast changing economical environment To increase production efficiency without reducing product quality To reduce cost To reduce production time To ensure non defective goods to customer

FAILURE PLANNING Discover Act Learn Plan Failure analysis - possibilities Recovery planning - procedures The facts - what has happened? The consequences Inform, contain and follow up Find the root cause Prevent it happening again

TYPES OF FAILURE Design failures Facilities failures Staff failures Failures inside the operation Supply failures Customer failures Environmental disruption

FAILURE DETECTION FAILURE ANALYSIS In-process checks Machine-diagnostic checks Point-of-departure interviews Accident investigation Product liability Complaint analysis Critical incident analysis Failure mode-and-effect analysis Fault-tree analysis FAILURE ANALYSIS

FAILURE MEASUREMENTS Failure Rate (FR) Reliability Availability Failure Rate (FR) – frequency Reliability – risk of failure Availability – productivity

FAILURE ANALYSIS AND RECOVERY PLANNING Failure detection and analysis Finding out what is going wrong and why Improving system reliability Stopping things from going wrong Recovery Coping when things do go wrong

BENEFITS WITH TPM 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 DIFFERENCES 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