1. 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

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

3. Methodologies
Source : Stamm et al (2009)

4. SCHEME WORLD CLASS MANUFACTURING
Source : TMA (2012)

5. 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)

6. 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)

7. DEVELOPMENT
Source : TPM Asia Guide (2002)

8. 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)

9. 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)

10. 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

11. 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!

12. Zulfa Fitri Ikatrinasari, Dr.