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TOTAL = All encompassing by maintenance and production individuals working together PRODUCTIVE = Production goods and services that meet or exceed customers’ expectations MAINTENANCE = Keeping equipment and plant in as good as or better than the original conditions at all times Productive maintenance (PM) originated in the U.S. in late 1940’s early 1950’s Japanese companies modified and enhanced it to fit the Japanese industrial environment The first use the term TPM was in 1961 by Nippondenso, a Japanese auto components manufacturer Seiichi Nakajima – head of JIPM, one of the earliest proponents, known as the Father of TPM
• • • • Laura Dietrich: Maintenance Manger Antoinette Lockett: Plant Manger Waseem Manzoor: Quality Manger Xiaoyan Liu: Production Manger Meeting Agenda I II Understanding Downtime -Group Major Losses of TPM -Antoinette Lockett I II III IV III Planned Downtime Losses -Xiaoyan Liu Unplanned Downtime Losses -Laura Dietrich Reduce Speed LossesPoor Quality Losses -Waseem Manzoor Total Productive Maintenance I II III IV V VI What is TPM -Antoinette Lockett Breakdown of TPM -Laura Dietrich TPM History -Laura Dietrich TPM Evolution Goal of TPM -Antoinette Lockett Three Principles of Prevention Meeting Agenda Cont I II TPM-8 Pillars-Laura Dietrich Kick off TPM I Launching TPM- Preparatory Stage-Antoinette Lockett II Autonomous Maintenance- Xiaoyan Liu III Equipment Management Life Cycle- Xiaoyan Liu IV TPM Implementation-Waseem Manzoor V Launching TPM- Stabilization-Waseen Manzoor VI Eliminating Equipment Losses-Laura Dietrich VII Improvement Goals for Chronic Losses-Laura Dietrich III Overall Equipment Efficiency IV I What is OEE-Xiaoyan Liu II III OEE Factors-Xiayon Liu Calculating OEE-Waseem Manzoor TPM Benefits-Xiaoyan Liu Understanding Downtime MAJOR LOSSES Planned Downtime losses • • • • Start-ups shift changes coffee and lunch breaks planned maintenance shutdowns Unplanned Downtime Losses • Equipment breakdown • Changeovers • Lack of material Reduced Speed Losses • Idling and minor stoppages • Slow-downs Poor Quality Losses • Process non-conformities • Scrap OEE What is OEE • OEE (overall equipment efficiency) is a “best practices” way to monitor and improve the efficiency of your manufacturing processes – machines – manufacturing cells – assembly lines OEE Factors • Plant Operating Time • Planned production time – planned downtime ie breaks • Availability – downtime losses • Performance – Speed losses • Quality – Quality losses World Class OEE OEE Factor World Class Availability 90.0% Performance 95.0% Quality 99.9 % OEE 85.0% Calculating OEE • Availability = Operating time/planned production • Performance = Ideal Cycle Time / Total Pieces or (total pieces / Operating time)/Ideal Run time • Quality = Good Pieces / Total Pieces • OEE = Availability X Performance X Quality Example OEE Calculation Item Data hrs = 480 Shift length Short Breaks 2@ 15 = 30 Meal Break @ 30 = 30 47 Down Time Ideal Run Time 60 pieces per 19,271 pieces Total Pieces 423 pieces Reject Pieces Availability = Operating time Planned production time • = 373 minutes / 420 minutes • = 0.8881 (88.81%) Performance = (Total pieces /Operating time) Ideal Run Time • = (19,271 pieces/373 minutes)/60 pieces per minute • = 0.8611 (86.11%) Quality = Good Pieces Total Pieces • = 18,848 / 19,271 pieces • = 0.9780 (97.80 %) OEE = Availability X Performance X Quality • = 0.8881 X 0.8611 X 0.9780 • = 0.7479 (74.79%) TPM BENIFITS TPM - Benefits • Improved equipment eliminates the root cause of defects • Defects are prevented through planned maintenance • Preventive maintenance costs are reduced as equipment operators conduct autonomous maintenance • Improved equipment designs ensure that new equipment naturally produces fewer defects • Simplified products designs and a redesigned process produce with few defects • Engineers, technicians and managers are trained in maintenance and quality TPM - Benefits (Japanese TPM Prize winners during 19821984) • Equipment failures reduced from 1,000/month to 20/month • Quality defects reduced from 1.0% to 0.1% • Warranty claims reduced by 25% • Maintenance costs reduced by 30% • WIP decreased by 50% • Productivity improved by 50% (Patterson & Fredendall, 1995) TPM – Success stories • USPS Albany, New York: annual save of $86,000; could save $4.5 million if applied nationwide • Yamato Kogyo Corp., Japan: - productivity up by 130%, - accidents cut by 90%, - defects reduced by 95%, - employee suggestion rate increased by over 300% [...]... Japanese auto components manufacturer • Seiichi Nakajima – head of JIPM, one of the earliest proponents, known as the Father of TPM TPM - Evolution • • • • Breakdown maintenance Preventive maintenance (PM) Productive maintenance Total productive maintenance Goals of TPM 1 Aims at getting the most effective use of equipment 2 Builds a comprehensive PM system 3 Brings together people from all departments concerned...TPM What is Total Productive Maintenance? • TPM is a plant improvement methodology which enables continuous and rapid improvement of the manufacturing process through use of employee involvement, employee empowerment, and closed-loop measurement of results Breakdown of TPM • TOTAL = All encompassing by maintenance and production individuals working together • PRODUCTIVE = Production goods... from all employees 8 Using teams for continuous improvement Three Principles of Prevention • Maintenance of normal conditions • Early discovery of abnormalities • Prompt response TPM 8 PILLARS 5s Safety, health and Environment Office TPM Training Quality Maintenance Planned Maintenance Kobetsu Kaizen Autonomous Maintenance PILLARS OF TPM Kick off TPM Launching TPM- Preparatory Stage • Announce top management’s... Implementation Launching TPM- TPM Implementation • Improve the effectiveness of each critical piece of equipment • Set up and implement autonomous maintenance • Establish a planned maintenance system in the maintenance department • Provide training to improve operator and maintenance skills • Develop an early equipment management program Launching TPM- Stabilization • Perfect TPM implementation and raise TPM... and production individuals working together • PRODUCTIVE = Production goods and services that meet or exceed customers’ expectations • MAINTENANCE = Keeping equipment and plant in as good as or better than the original conditions at all times TPM - History • Productive maintenance (PM) originated in the U.S in late 1940’s & early 1950’s • Japanese companies modified and enhanced it to fit the Japanese... Availability 90.0% Performance 95.0% Quality 99.9 % OEE 85.0% Calculating OEE • Availability = Operating time/planned production • Performance = Ideal Cycle Time / Total Pieces or (total pieces / Operating time)/Ideal Run time • Quality = Good Pieces / Total Pieces • OEE = Availability X Performance X Quality