Total Productive

Maintenance
Yogesh Shastri
QUICK
SERVICE
 Skip
Preventive
Maintenance

More Quick
Breakdowns Repairs

PM time
More
further
Breakdowns
reduced
 Overall Equipment Effectiveness
OEE = Availability x performance rate x Quality rate

World Class Companies

• Availability > 90 %
• Performance rate > 95 %
• Quality rate > 99 %
• OEE > 0.90 x 0.95 x 0.99 = 85 %

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 OEE < 85 % ?
Do we have ?
• A leader with a vision ?
• A maintenance policy in place ?
• A committed workforce ?
• Operator friendly equipments ?
• A clean and safe working environment ?
And still…..

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 Evolution of Maintenance
Management Systems

• Breakdown Maintenance
• Preventive Maintenance
• Predictive Maintenance
• Reliability Centered Maintenance

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 Evolution of Maintenance
Management
• Reliability Centered Maintenance
• Total Employee Involvement
• Total Quality Management

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Do these problems sound familiar ?
• Downtime losses
• * Breakdowns
• * Setup and adjustment losses
• Speed Losses
• * Equipment operates below rated capacity
• * Idling and minor stoppages
• Defect Losses
• * Defects in process
• * Reduced yield

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Then… what are we missing out ?
• Continuous and rapid improvements
• Effectiveness of equipment
• Employee skill and morale
• Total group involvement
• “I operate – I know – I fix” attitude
In Short :
TOTAL PRODUCTIVE MAINTENANCE

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 Features of Total Productive
Maintenance
• Emphasis on Overall Equipment Effectiveness
• Life Cycle Approach
• Autonomous Maintenance
• Enterprise wide participation
• Cohesive group working

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Total Productive Maintenance
The Corporate cultural change

Zero Breakdowns
Zero Defects
Zero Accidents

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 Implementing TPM
Basic Requisites
• A working maintenance strategy firmly in
place.
• Quality environment implementing 5s. 5s is a
very effective approach to improving our work
environment and total quality. It becomes a
base for continuous improvements

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 What is 5 S ?
• The Term 5S represents 5 Japanese words.

Seiri Sort
Seiton Straighten
Seiso Shine
Seiketsu Standardize
Shitshuke Sustain
• But that doesn’t means that you have to be Japanese
to practice 5s.
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Total Productive Maintenance 19
 Autonomous Maintenance
Autonomous Maintenance
is a phrase coined by the

Japan Institute of Plant Maintenance

to describe the shift toward machine operators

maintaining their own equipment.

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Operator Autonomous Maintenance- Jishu Hozen

7 Steps

T P M

Aut. Mgt. 77
Standardization 66
Autonomous Inspection
55
OIL
General Inspection
44
Prepare Temporary Standards
33
Countermeasures for Contamination
22
Initial Clean-up
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 Autonomous Maintenance
Old Attitude
• I operate - you fix
• I fix - you design
• I design – you operate
TPM approach
• We are all responsible for our equipment
Key tip
• Progress requires change, if we do not change we will
never progress.

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 Focused Improvement –
Kobetsu Kaizen
• Cross-functional teams assembled
• Working on problematic equipment and
coming up with improvement suggestions.
• Kaizen projects for maintenance also
serve as training sessions
• Choose at least one piece of equipment as
a pilot for their activities.
• Problems relating to the equipment are
identified and Total
improvement
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goals set 23
 Focused Improvement –
Kobetsu Kaizen
• Participants map the current state of
affairs as a baseline performance measure
• The teams work together to make sure
that any solutions that they come up with
are implemented
• Quick gains are made which helps in
promoting the lean methodology to
workers who may not have bought in to
the program.
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 Early Equipment Maintenance
• Ease of cleaning and inspection
• Ease of lubrication
• Accessibility of equipment parts
• Improving operability of machines through
ergonomically placing
• Making it easier for changeover to take place
• Feedback mechanisms that prevent out-of-spec
situations
• Increased safety features
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 Implementing TPM
Preparation stage
• Corporate commitment
• TPM awareness campaign
• Organization setup
• TPM policy and goals
• TPM master plan

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 Implementing TPM
Implementation stage
• TPM kick off
• OEE improvement (Pilot projects & teams)
• Autonomous maintenance (Step by step)
• Planned maintenance
• Personnel training

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 Implementing TPM
Perfection stage
• Equipment design improvement
• Spreading to other fields
• TPM audit and review
• TPM awards

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The role of Maintenance in TPM
• Provide technical support and training to
operators
• Restore deteriorated equipments
• Identify design weaknesses and improve the
equipment to error free function
• Improve technical maintenance skill of
maintenance personnel through training
• Implement planned and preventive maintenance
based on data provided by operators.

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 The role of Maintenance in TPM
• Through data analysis and periodic diagnostic
tests, perform appropriate maintenance to
avoid predicted equipment failure
• Maintain work order system and collect data
• Ensure that the maintenance function is
addressing the root cause and not the symptom
• Understand the manufacturing process to
achieve the above successfully and capability
to operate the equipment.
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 Small Group Activities
• Meetings
• Actual autonomous maintenance
• Education and training
• Improvement in activities – case studies and
recognition
• Integration of small group into organizational
structure
• Evaluating the maturity of small group activity
• Commitment and support of top management
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 Latest trends in Maintenance
• Additive Manufacturing in Maintenance
• Internet of Things, Wireless Sensor
Networks and Automated Data Collection
• Augmented Reality for Training and
Remote Maintenance
• Maintenance as a Service
• Supply Chain Collaboration

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TPM is a lean tool for quality and productivity

Thank you for your kind attention

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 Effectiveness of Maintenance
Reflected by equipment effectiveness:
• Maintainability
• Reliability
• Availability
• Efficiency
• Quality rate

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 Maintainability
One measure is Mean Down Time (MDT)
MDT = Mean downtime
MTTR = Expected time for actual restoration
MWT = Expected time before restoration starts
MDT = Total downtime / Number of failures
MDT = MTTR + MWT

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 Reliability
• Probability machine will perform properly
during normal operating conditions.
• Failure patterns
• Wear-out failure
• Burn-in failure
• Can be improved by proper maintenance
• The Measure of Reliability is Mean Time
before failure (MTBF)
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 Mean Time Before Failure
• Mean time before failure is a measure of Reliability
• Mean Time Before failure = Expectation of the
operation time between failure

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 Availability
• Proportion of time machine is actually available out
of time it should be available
• Availability A is given as:

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 Efficiency
• Rate efficiency (RE)
– Actual average cycle time is slower than design cycle time
because of jams, etc.
– Output is reduced because of jams
• Speed efficiency (SE)
– Actual cycle time is slower than design cycle time
– machine output is reduced because it is running at reduced
speed
• Performance Efficiency (PE)
PE = RE x SE

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 Quality Rate
• Percentage of good parts out of total produced
• Sometimes called “yield”

Q = Quality produce / Total produce

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