10 TOTAL PRODUCTIVE MAINTENANCE (TPM) Zulfa Fitri Ikatrinasari, Dr. Overview of TPM Failure Mode Effects Analysis (FMEA) Zulfa Fitri Ikatrinasari, Dr. Ekonomi dan Bisnis Manajemen

Relationship between TPM and lean manufacturing philosophies Source : Ahuja and Khamba (2008)

Methodologies Source : Stamm et al (2009)

SCHEME WORLD CLASS MANUFACTURING Source : TMA (2012)

How much time do you have ? The Journey of Operating Excellence $MM Six Sigma Efforts -new major projects -variability reduction Optimize Improvement Projects -Scrap reduction -SMED -Poka Yoke -TPM Lean Efforts -One piece flow -Cellular Mfg -Kanban Productivity Lean Efforts -5S -measurement -standard Work Improvement Six Sigma Efforts -quality -productivity Stabilize Time How much time do you have ? Source: Lean Expert Training (2002)

Preventive Maintenance Maintenance Strategy Pyramid Continuous Improvement Total Productive Maintenance Financial Optimization Predictive Maintenance Operations Involvement Reliability Centered Maintenance Stores and Procurement Work Flow System CMMS Technical and Interpersonal Training Preventive Maintenance Source :Terry Wireman (2004)

DEVELOPMENT Source : TPM Asia Guide (2002)

FMEA Why Methodology that facilitates process improvement Identifies and eliminates concerns early in the development of a process or design Improve internal and external customer satisfaction Focuses on prevention FMEA may be a customer requirement (likely contractual) FMEA may be required by an applicable Quality Management System Standard (possibly ISO)

FMEA A structured approach to: Identifying the ways in which a product or process can fail Estimating risk associated with specific causes Prioritizing the actions that should be taken to reduce risk Evaluating design validation plan (design FMEA) or current control plan (process FMEA)

When to Conduct an FMEA Early in the process improvement investigation When new systems, products, and processes are being designed When existing designs or processes are being changed When carry-over designs are used in new applications After system, product, or process functions are defined, but before specific hardware is selected or released to manufacturing

This is the template we use to create our FMEA’s What are the Benefits? Action FMEA Failure Mode Effects Analysis What is it? Introducing New Processes and Products can be risky! FMEAs identify potential Failures and their causes before they happen. Prioritises potential Failures according to their Risk Drives improvement actions to eliminate or reduce the problem from happening Provides a documented & structured way of capturing data & action This is the template we use to create our FMEA’s All areas must be completed to look at the possible risk for this changed Process or Product type. If you are introducing a New Process or Product, you will benefit from carrying out an FMEA – Ask!

Zulfa Fitri Ikatrinasari, Dr.