Total

Productive
Maintenance
TPM
Total Productive Maintenance (TPM) is a
maintenance program concept. Philosophically, TPM
resembles Total Quality Management (TQM) in
several aspects, such as:

(1)total commitment to the program by upper level

management is required,
(2) employees must be empowered to initiate
corrective action, and
3) a long range outlook must be accepted as TPM
may take a year or more to implement and is an on-
going process.
Changes in employee mind-set toward their job
responsibilities must take place as well.
 What For TPM?

•TPM brings maintenance into focus as a

necessary and vitally important part of the
business.
•It is no longer regarded as a non-profit activity.
• Down time for maintenance is scheduled as a
part of the manufacturing day and, in some cases,
as an integral part of the manufacturing process.
•It is no longer simply squeezed in whenever
there is a break in material flow.
•The goal is to hold emergency and
unscheduled maintenance to a minimum.
 What is TPM?

T Total • Overall efficiency.

• Total production system.
• Participation of all employees.

P Productive • Zero defect.

• No trouble in operation.
• Safety.

M Maintenance • Longer life cycle of production

system.
 What is TPM?
• Aims at “Breakthrough improvement in productivity and
reducing chronic losses to zero”.
• Aims at “Creating a bright, clean, and pleasant factory”.
• Means “To reinforce people and facilities and through them, the
whole organization”.
• Addresses “Overall equipment effectiveness”.
• Institutionalizes “Total Employees Involvement” – “Participative
management” and an “Overall-small group organization”.
• Eliminates inter departmental walls and facilitates Cross Functional
Management.
• Is material oriented; it seeks to keep equipment in its intended
condition.
 TPM Results in…
• Results in building up corporate culture that
thoroughly pursues production
• System efficiency improvement OEE (Overall
Equipment efficiency-)
• Constructs a system to prevent every kind of loss, for
example “Zero accidents, Zero defects and Zero
failures” based Gemba (Work Place) and Genbutsu
(actual thing) over the entire life cycle of a production
system.
• Covers all departments including production, Quality
Control, Purchase, marketing, Administration, Design
& development, Maintenance & Engineering.
• Requires all and full involvement from top
management to frontline employees. It builds up an
overlapping multidiscipline process based
management teams to achieve excellence
 What is OEE?

Overall Equipment Efficiency

OEE = A x P x Q

A= Availability
P= Performance
Q= Quality
 How to Calculate OEE?
Availability Standard time – downtime
=
Standard time

Components Produced
Performance =
Components supposed to be Produced

Total Acceptable Components

Quality =
Total Components produced
Lean System
Peak Performance

Pull system / flow production

Rapid Changeover / Customer-driven lot size
Continuous Waste Reduction
Lean Measures

5S Standardized
Visual TPM Work
Factory

Variation reduction / Six Sigma

In-Station Process Control
Leadership by Example & Commitment
Employee Involvement & Mutual Respect
7 Types of Waste

1. Over Production waste

2. Inventory waste

3. Conveyance waste

4. Defect production waste

5. Idle time waste

6. Process related waste

7. Operation related waste

Causes of Waste
 Excess Manning
◦ Poor layout and material presentation
◦ Rework and extra processes
◦ Inconsistent / inefficient work methods
 Excess Downtime
◦ Tooling condition
◦ Unreliable equipment
◦ Long changeovers
◦ Incapable process
 Defectives - Rework or Replace
◦ Incapable processes or process not compatible
with customer expectations or design spec (design
for mfg)
◦ Tooling condition
◦ Operator methods and errors
Effective TPM Eliminates 5 Losses

1. Equipment breakdowns
2. Defects, scrap, and rework
3. Safety Issues
4. Mini stoppages
5. Reduced speed
 What is TPM??
TPM is a Lean tool to optimize the
effectiveness of manufacturing equipment and
tooling.
1. Starts with 5S / Visual Factory
2. Builds a comprehensive Downtime Database
by cause, frequency, and duration
3. Predicts and prevents downtime by PM system
4. Expands role of Operator as first point of early
warning and prevention
5. Develops Professional Maintenance skills
 Operator Autonomous Maintenance

Seven Steps
of TPM
Aut. Mgt. 7
Standardization 7 6

Autonomous Inspection 6 5
5
General Inspection 4
4
Initial Standards 3
3
22
Countermeasures for Contamination

Initial Clean-up
11
 5S Workplace
A safe, clean, orderly workplace is
fundamental to quality, efficiency, and
teams
Sort (organize)
Shine (clean)
Set in order (make orderly and neat)
Standardize (visual place for everything)
Sustain (maintain the system)
 TPM starts with 5S
 You can’t see problems clearly when the
workplace is in disarray
 Cleaning and organizing the workplace
helps the team to uncover problems
 Making problems visible is the first step of
improvement
 Clean machines and workplace create pride
& Safety
Downtime Visual Controls
 Visual or audio alerts
◦ Abnormality obvious at a glance (e.g.
stoppage, reject, control fault)
◦ Alerting Maint and team leaders
◦ Provide real time “scoreboard” for employees
 Machine down light visible from aisle
 Production status board (e.g. actual counts vs. goal)
 Scrap counts and downtime minutes
 Located in clear view in shop (not in control room)
 Simple, self regulating, & employee managed
 Downtime Database
 Categorize at a minimum by Equip, Tooling, C/O, Other
 Segmented bar graph for E-T-O lost time
 Subcategories for Equip (e.g.)
◦ Hydraulic / pneumatic
◦ Mechanical / lubrication
◦ Electrical / controls
◦ Shot-end components
 Subcategories for Tooling (e.g.)
◦ Slides
◦ Cores
◦ Inserts
◦ Ejector pins
 Subcategories for Other (e.g.)
◦ Operator error
◦ Materials
 Minimum Downtime Tracking
Downtime by Cause 3500 ton Bay
Other (avg min/shift per Machine)

120
Tools
100

80
O
Minutes 60
T
40 E

20
Equip
0
1Q02 2Q02 Jun Jul Aug Sep Oct Nov Dec
 Predictive Maintenance Tools
 Rate/hr vs. target or historical normal output (B/W)
 Database
◦ MP2 / maintenance history
◦ statistical probability (frequency & duration)
 Physical prediction of impending failure
◦ Sound (bearing)
◦ Temperature (cooling water)
◦ Flash (core pins)
◦ Shot monitoring system
◦ SPC on part geometry
◦ Hydraulic pressure (ejector pins)
◦ Spindle loads (amps)
◦ Fluids / Lubrication analysis (milipore)
◦ Vibration Signature Analysis
Preventive Maintenance System
 History of downtime by major machine & tool
◦ Downtime measurement & tracking
◦ Mean Time Between Failures
◦ Average downtime
◦ Pareto of causes at component level (eg L/S or temp sensor)
◦ Cost to maintain
 Develop PM cards based on frequency of failure and magnitude of
average lost time (start small & grow)
◦ Limit & prox switches
◦ Shot tip / sleeve
◦ Critical frame and cylinder mounting bolts
◦ Expendable tools
◦ Valves, hoses, packing, seals
 PM’s have instruction, schedule/frequency & sign-off
◦ PM’s / repairs done in window of opportunity when machine is down
◦ Cycle count or date based execution of PM’s (eg cutter change)
◦ PM status visual (work completed / not completed)
 TPM

Production Operators
• Clean & Check
• Observe
• Categorize

Production Planning &

Active Quality Engineers
Control Planned • Standards &
• Schedule P.M. Maintenance Calibrations
Process
Manufacturing Engineers
• Equipment Planning
• Equipment Studies
 OMP - Operator Maintenance Partnership

 Operator training in TPM

 Operator basic equip inspection &
tooling checks TPM
 Operator basic cleaning
 Operator lubrication check
 One point lessons (capture
knowledge)
 TPM Board & TPM Tags (proactive
operator involvement)
 TPM Tag System
 Problem communication tool to and from
maintenance, tool room, and production
◦ Identify abnormal machine conditions
 Record problem discovered by operator
 Record problem found during scheduled PM
◦ Status tracking system of requested repairs
◦ TPM visual management tool (hang tags)
◦ Repair history for future problem solving
 TPM Tag used for recording problem & fix
◦ Blue Tag-Operator or Maint responsible to repair
◦ Red Tag- Safety-related request (priority)

Operator/Supervisor
1. Abnormality Identified
2. Fill out Tag Red= Safety
Blue= Prod/Maint
3. Hang C-tag as close to the defect
as possible
4. Hang A &B Tags on the TPM Tag
status board by Machine location and
area of responsibility to correct.
7. Operator/Supervisor check to see
if work was done.
8. If OK, Operator/ supervisor
removes C tag from machine and
places ABC tags in Completed box. If
not OK, tags stay and maint is
contacted. Contact noted on tag.
Tag Process
Production Management
9. Production management reviews
the information. Also reviews the
comments and takes actions if
required. Places tag in history file box
located in the office
Maintenance
5.Maintenance evaluates problem. If
fixed immediately go to 6. If parts or
time needed, maint pulls A tag from
board. The A tag is MWO. The B
tag is posted on the Maint WO
status section of the TPM Board with
est. timing.
6.After work is completed,
maintenance completes back side of
A tag and places both the A & B tag
in the work completed box

Tag information is recorded and reviewed for continuous improvement of PM

database by Production and Maintenance; Repeat operator tags may indicate
Maint needs to investigate.
 Professional Maintenance
 Equip Safety
 Skill building
 Cross-training
 Area Maintenance
 WC MRO stores
 Maint Mgmt System
 Down alarms
 Radios
 Planned PM
 TPM
Initial Focus

TPM I TPM II
Step 1 Step 4
5S Step 2 Step 5
Step 3 Step 6
Step 7

prerequisite for TPM I

 STEP 3: Prepare Temporary Standards
This step is to enhance the equipment reliability &
maintainability.
 Temporary Check Sheet For Clean-Up,
Lubrication, Start-up, and Shut-down:
◦ What items need to be done
◦ Who will perform the check
◦ How often to check
◦ Where the location is to be checked
◦ What to use for the inspection or cleaning
◦ Target time to complete the task
 TPM Summary
 TPM = Total Productive
Maintenance
◦ Proactive (all employees
involved) Peak Performance

◦ Preventive
◦ Predictive Continuous Waste Reduction
◦ Planned
 TPM is an integral part of 5S Standardized
TPM
JLF Total Quality Visual Work
Factory
production System
TPM is a Lean tool for
Quality and Productivity