1. IENG 451 / 452 Stability: Total Productive Maintenance
IENG Lecture 18
Stability:
Total Productive Maintenance
7/19/2018
IENG 451 Operational Strategies
(c) D.H. Jensen

2. House of Lean CUSTOMER FOCUS JUST IN TIME INVOLVEMENT JIDOKA
Hoshin Planning, Takt, Heijunka
Involvement, Lean Design, A3 Thinking
JUST IN TIME
INVOLVEMENT
JIDOKA
Standardized Work 5S
TPM
Kaizen Teams
Suggestions
Safety Activities
Hoshin Planning
Flow
Heijunka
Takt Time
Pull System
Kanban
Visual Order (5S)
Robust Process
Involvement
Poke Yoke
Zone Control
Visual Order (5S)
Problem Solving
Abnormality Control
Separate Human & Machine Work
Involvement
STANDARDIZATION
Standardized Work
Kanban, A3 Thinking
Visual Order (5S)
Hoshin Planning
STABILITY
Standardized Work, 5S, TPM
Jidoka, Heijunka, Kanban
7/19/2018
IENG 451 Operational Strategies

3. TPM: Total Productive Maintenance
Leveraging on Productivity:
Old World Mfg – alienation of workers and management fostered strict job descriptions. Among these job divisions were engineering, maintenance, and line (production) workers. This led to the operating principles that: 1. Engineers design; Production produces; and 3. Maintenance fixes.
New World Mfg – requires teamwork in order to survive and thrive. Coordinated teamwork requires sharing of knowledge and responsibilities – even cross-training.
Once Production Stops, All Action Becomes Non-Value-Added – so both mfg. systems could claim that they needed to avoid production stoppages – the difference in the lean system thinking is how effective you can become when teaming is involved.
7/19/2018
IENG 451 Operational Strategies

4. TPM Allows Task Shifts to Occur
When we maintain for total productivity, tasks shift
and communications improve!
Maintenance Departments
(20% – 50%)
Overhauls
Equipment Improvement
Training
Maintenance Prevention
Predictive Maintenance
Maintenance Tasks Transferred to Production:
Simple maintainability kaizen
Cleaning
Inspection
Lubrications
Adjustment
Engineering Departments
Design for Maintainability
Equipment Improvement
7/19/2018
IENG 451 Operational Strategies

5. TPM: Transformation Steps
Even Old World systems worried about productivity and maintenance, but Lean Systems allow us to leverage the data and personnel more productively.
Staging a transition to TPM:
Stage 1: Breakdown Maintenance – (fire-fighting mode) When a breakdown occurs, all efforts are immediately focus and resources immediately committed to getting the system back up and running. (Probably already being done…)
Stage 2: Preventative Maintenance – requires some planning for proactive maintenance and expedited trouble shooting.
Stage 3: TPM – includes preventative maintenance but adds predictive maintenance and total involvement to avoid the six big losses for machine effectiveness.
7/19/2018
IENG 451 Operational Strategies

6. IENG 451 Operational Strategies
TPM: The Six Big Losses
These losses downgrade machine effectiveness:
Downtime Losses
Equipment Breakdowns
Setup and Adjustment Delays
Speed / Hidden Losses
Idling and Minor Stoppages
Reduced Speed Operation
are sometimes due to mismanagement (starved or blocked processes)
Defect Losses
Processing Defects
Reduced Yield
7/19/2018
IENG 451 Operational Strategies

7. IENG 471 Facilities Planning
TPM Term Definitions
Reliability is a measure of how often a system fails:
How long (on average) you can run it until it stops working right
How do you know that it’s not working right?
MTTF (Mean Time To Failure) or
MTBF (Mean Time Between Failures)
7/19/2018
IENG 471 Facilities Planning

8. IENG 471 Facilities Planning
TPM Term Definitions
Maintainability (serviceability) is a measure of how long it takes to return the system to proper operation:
It is the sum of the times required to:
diagnose the problem
obtain repair parts / tools
repair the failed components
return the unit to operating conditions
MTTR (Mean Time To Repair)
7/19/2018
IENG 471 Facilities Planning

9. IENG 471 Facilities Planning
TPM Measurements:
Availability is a function of Reliability and Maintainability:
It is the percentage of time that you can count on using the resource for production
Note: this is different from how the Dennis text defines Availability – but is more consistent with other uses of the concept and rarely differs
% Availability = MTTF
MTTF + MTTR
7/19/2018
IENG 471 Facilities Planning

10. IENG 471 Facilities Planning
TPM Measurements
Performance Efficiency is a measure of efficiency when the resource is running:
where:
Operating Time is the time the resource is scheduled to run or is running (whichever is the maximum)
Lost Time is the time that the resource is Available, but not productive
% Perf. Efficiency = Net Operating Time – Lost Time
Net Operating Time
7/19/2018
IENG 471 Facilities Planning

11. IENG 471 Facilities Planning
TPM Measurements
Overall Equipment Efficiency is a measure of efficiency when we take (poor) quality losses into consideration:
where
Quality Rate is the proportion defective for the process (p from a p-chart or np-chart)
Frequently, the OEE struggles to get to 50%!
% OEE = Availability X Perf. Efficiency X Quality Rate
7/19/2018
IENG 471 Facilities Planning

12. IENG 451 Operational Strategies
Machine Losses
Machine Losses over the lifetime take on a bathtub curve:
Start-up Failures – Design & manufacturing errors
Trial Runs
Commissioning Process
Chance Failure – operational errors; minor and hidden failures
Control Charts
Counter Measures
Wear-Out Failures – End of Life (wear & fatigue) failures
Prevention
Improved Maintainability
Often, these take the shape of a pyramid:
Breakdown 1
Minor Stoppage 10
Minor Failures 30
Hidden Failures 100+
7/19/2018
IENG 451 Operational Strategies

13. IENG 451 Operational Strategies
Questions & Issues
7/19/2018
IENG 451 Operational Strategies
(c) D.H. Jensen