Total Productive Maintenance Dr Neil Towers Fashion Operations Management

Learning Objectives To understand the concept of Total Productive Maintenance (TPM) To be able to assess the impact of failure for a fashion operation

Definition “the maintenance management carried out by all employees through small group activities that recognises the importance of reliability, service and efficient operation” Adapted from Slack et al, 3 rd ed, 2001, p659

Why systems fail Design failures Facilities failures Staff failures Failures inside the operation Supply failures Customer failures

Causes of Failure Design failures Facilities failures Staff failures Supplier failures Customer failures

How failure is detected and analysed Failure detection mechanisms include: -in-process checks; -machine-diagnostic checks; -point-of-departure interviews. Failure analysis procedures include: -accident investigation; -failure mode-and-effect analysis; -fault-tree analysis.

5 Goals of TPM Improve equipment effectiveness Achieve autonomous maintenance Plan maintenance Train all staff in relevant maintenance skills Achieve early equipment management

Recovery strategies for dealing with failure Plan Discover Act Learn 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

Failure analysis Accident investigation Product liability Complaint analysis Critical incident analysis Failure mode and effect analysis

Assessing Failure Failure rate Reliability Availability

How failure is measured Time Wear-out stage Normal-life stage Infant- mortality stage Failure rate

Fashion Operations issues Extended geographic supply chains –Long distances –High transit times Multiple intermediaries –Agents, Wholesalers, Logistics operators Customer Service Intensive selling season –Compressed timescale High customer expectations –Focus on satisfaction