Lean Manufacturing Total Productive Maintenance

If Your Equipment Isnt Available to Run at Full Capacity, Youre Not Maximizing Your Profit Potential.
Total Productive Maintenance (TPM) is the key to optimizing the productivity of your equipment throughout its life. The TPM process addresses both downtime and reliability.
Lean Manufacturing is probably the single most important methodology available today to help manufacturers improve productivity in almost any part of their business, thereby improving the ability to compete, grow, and be profitable. TPM is a building block in the process toward Lean, and addresses your equipments reliability, with respect to productivity. TPM is designed to help keep every machine ready to perform its necessary function at all times. In Lean language, this is referred to as Overall Equipment Effectiveness (OEE). It also addresses elimination of waste, and shared responsibility for equipment reliability, optimizing the workforce, too.

OEE Equals:
(Availability) x (Performance Efficiency) x (Rate of Quality of Products)

TPM from the DVIRC

The DVIRC Lean Manufacturing Team delivers a complete TPM program, from assessment to solutions. Our team is nationally certified through the National Institute for Standards and Technology (NIST) with diverse professional and practical manufacturing, and Lean, experience. Our four-step process will result in a final report that outlines the current state of the equipment through performance measurements and the steps that need to be taken to change the process, to yield improved performance.

The TPM Process

Step One: Educate and Assess Identify your team; those that both work on and are responsible for the equipment, productivity, quality and maintenance. We will then take them through the assessment process, what to look for and how to tackle the problems. OEE will be introduced as the major measurement tool we will utilize to achieve turnaround. Step Two: Plan and Prepare As a team, we will identify the opportunities for improved productivity. We will select a pilot area to enable the team to focus and learn the methodology before applying it in a broader sense. Step Three: Pilot Process With the pilot area identified, we will work with your team to: - Restore the equipment - Identify how to prevent deterioration - Identify the root cause of all failures - Eliminate set up and adjustments - Based on Lean SMED {Single Minute Exchange of Dies} principles - Identify and eliminate minor stoppages - Identify root cause of all product defects - Study equipment performance Step Four: Rollout Full Implementation Once the pilot is complete, the DVIRC team will help the team transfer their knowledge to other areas. The team can continue to focus on areas until the plant is complete. TPM has a very high success rate in improvement of equipment effectiveness, ownership of equipment productivity and maintenance, increased maintenance skills, more effective management of equipment and even predictive maintenance. According to NIST, typical manufacturers are experiencing up to 65% OEE improvements, quality improvements up to 50% and maintenance expenditure reductions of up to 50%. To learn more about TPM or Lean Manufacturing, call the DVIRC and ask for the representative in your county. Theres never a charge for our initial consultation. We even offer a free two-hour Lean Overview to help manufacturers understand all the key principles of Lean and how they relate to your business.

The Delaware Valley Industrial Resource Center 2905 Southampton Road Philadelphia, PA 19154-1270 Bucks County Mike Renner mrenner@dvirc.org Chester County Ray Malicki rmalicki@dvirc.org

Tel: (215) 464-8550 Fax: (215) 464-8570 www.dvirc.org Montgomery County Keith Ashlock kashlock@dvirc.org Philadelphia County Ralph Jones rjones@dvirc.org

Delaware County Ray Malicki rmalicki@dvirc.org

Copyright DVIRC, 2003. The Delaware Valley Industrial Resource Center is an affiliate of National Institute of Standards and Technology's Manufacturing Extension Partnership. Printed in the U.S.A. v1.0 (5/2003)