A company-wide team-based effort to build quality into equipment and to improve overall equipment effectiveness

Total

• all employees are involved

• it aims to eliminate all accidents, defects and breakdowns

Productive

• actions are performed while production goes on

• troubles for production are minimized

Maintenance

• keep in good condition

• repair, clean, lubricate

TPM combines the traditionally American practice of preventive maintenance with Total Quality Control and Total Employee Involvement, to create a culture where operators develop ownership of their equipment, and become full partners with Maintenance, Engineering and Management to assure equipment operates properly everyday.

• Dr. Deming introduced statistical analysis and used the resulting data to control quality during manufacturing (TQM)

• Some general concepts of TQM did not work well in the maintenance environment

• The need to go further than preventive maintenance was quickly recognized by those companies who were committed to TQM

• Maintenance became an integral part of TQM in the early 90’s

• Increase Overall Equipment Effectiveness (OEE)

• Improve existing planned maintenance systems

• The operator is the best condition monitor

• Provide training to upgrade operations and maintenance skills

• Involve everyone and utilize cross-functional teamwork

Train the operators to close the gap between them and the maintenance staff, making it easier for both to work as one team

Change the equipment so the operator can identify any abnormal conditions and measure deterioration before it affects the process or leads to a failure

7 steps are implemented to progressively increase operators knowledge, participation and responsibility for their equipment

1. Perform initial cleaning and inspection

2. Countermeasures for the causes and effects of dirt and dust

3. Establish cleaning and lubrication standards

4. Conduct general inspection training

5. Carry out equipment inspection checks

6. Workplace management and control

7. Continuous improvement

Objective: maximize efficiency by eliminating waste and manufacturing losses

Manufacturing losses are categorized into 13 big losses:

•          Equipment losses (6)

•          Manpower losses (4)

•          Material losses (3)

OEE figures are determined by combining the availability and performance of your equipment with the quality of parts made

OEE measures the efficiency of the machine during its planned loading time. Planned downtime does not effect the OEE figure.

Objective: establish Preventative and Predictive Maintenance systems for equipment and tooling

Natural life cycle of individual machine elements must be achieved

• Correct operation

• Correct set-up

• Cleaning

• Lubrication

• Retightening

• Feedback and repair of minor defects

• Quality spare parts

Objective: establish systems to shorten

•          new product or equipment development

•          start-up, commissioning and stabilization time for quality and efficiency

New equipment needs to be:

•          easy to operate

•          easy to clean

•          easy to maintain and reliable

•          have quick set-up times

•          operate at the lowest life cycle cost

Definition: a process for controlling the condition of equipment components that affect variability in product quality

Objective: to set and maintain conditions to accomplish zero defects

Quality rate has a direct correlation with

•          material conditions

•          equipment precision

•          production methods

•          process parameters

Administrative and support departments can be seen as process plants whose principal tasks are to collect, process, and distribute information

Process analysis should be applied to streamline information flow

TPM is a continuous learning process.

2 major components

• soft skills training: how to work as teams, diversity training and communication skills

• technical training: upgrading problem-solving and equipment- related skills

Assuring safety and preventing adverse environmental impacts are important priorities in any TPM effort.