Total Productive Maintenance and Maintenance Management Lean Manufacturing Series

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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

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

Autonomous Maintenance 7 steps are implemented to progressively increase operators knowledge, participation and responsibility for their equipment 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

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

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

The Strategic Importance of Maintenance and Reliability Failure has far reaching effects on a firm’s operation reputation profitability customers product employees profits The effect of failure on the listed items should be discussed. A point to make is that the cost of failure implies more than simply “this unit doesn’t work.” It reduces the likelihood of return customers in many ways.

Tactics for Reliability and Maintenance Reliability Tactics improving individual components providing redundancy Maintenance Tactics implementing preventive maintenance increasing repair capabilities You might discuss the meaning of redundancy.

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 Ask students to identify some of the pros and cons of the various possibilities.

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