1. TOTAL PRODUCTIVE MAINTENANCE
‘Failure prevention’

2. LEARNING OUTCOMES
…to understand the concept of Total Productive Maintenance (TPM)
…to understand the impact of failure for a fashion operation

3. 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.”

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

5. 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

6. 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

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

8. 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

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

10. 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

11. 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

12. 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