Total Productive Maintenance

(TPM)

Lszl Sos

TPM Third Country TC-print

OUTLINE

Types of maintenance
Total maintenance system
The six big losses reduce the efficiency
The 5 causes of breakdown
Breakdowns and reliability
The importance of the loss deployment

TPM Third Country TC-print

PEOPLE, EQUIPMENT, TECHNOLOGY

In the competitive environment the technology is the physical
manifestation of the knowledge.
TECHNOLOGY
CAD
Computer Modeling
CNC Machines
Assembling robots
Automatic Control
Automatic store
..

HOW THE TECHNOLOGY

EFFECT THE BUSINESS
Design
Production
Operation
Delivery

Easy to sell product

Required quality
Low cost
Short lead time

MAINTENANCE
It makes easy for the technology to perform appropriate effect for business

TPM Third Country TC-print

TYPES OF THE MAITENANCE

164 COMPANIES WON TPM AWARDS FOR THE EXCELENT PLANT MAINTENANCE IN 2003
(JIPM Japan Institute of Plant Maintenance)

1970-

COMPANY WIDE
DOING BY THE PRODUCTION &

TPM

MAINTENANCE

REPAIR

CONDITION BASED

1950-

AGAINST BREAKDOWN

PREVENTIVE MAINTENANCE

TIME BASED

-1950

NO MAINTENANCE,
ONLY REPAIR

OPERATION UNTIL BREAKDOWN

REPAIR

Breakdown
can happen any time
TPM Third Country TC-print

MAITENANCE POLICY
OPERATION
UNTIL
BREAKDOWN

BREAKDOWN

REPAIR

RELIABILITY
BASED
MAINTENANCE
FAILURE
DETERMINATION
PREVENTIVE
MAINTENANCE
(PROFESSIONAL)

WHEN?
HOW?

CONDITION
BASED

TIME BASED

TPM
AUTONOMOUS
MAINTENANCE

PRACTICE

VIBRATION
TRIBOLOGY
TEMPERATURE
ELECTRICAL
GENERAL REPAIR
OILING
LUBRICATION
CLEANING

CONTINUOUS
IMPROVEMENT

TPM Third Country TC-print

TOTAL MAINTENANCE SYSTEM

REPAIR

Professional
maintenance
PREVENTIVE MAINTENANCE

CLEANING, LUBRICATION

Autonomous
maintenance
PAYING ATTENTION TO ABNORMALITY

TPM Third Country TC-print

TPM ( TOTAL PRODUCTIVE MAINTENANCE )

What is TPM ?

TPM is an acronym of Total Productive Maintenance and

its more advanced form Total Productive Management.
TPM combines the American Preventive Maintenance practice and
the Japan Total Quality Control.
The result is an innovative system what optimizes the efficiency,
prevents machine breakdowns and support
the autonomous maintenance in the daily practice.

TPM Third Country TC-print

TPM ( TOTAL PRODUCTIVE MAINTENANCE )

The scope of TPM

Reduction of the machine breakdown

Reduction of the repair time

Quality improvement

TPM Third Country TC-print

TPM ( TOTAL PRODUCTIVE MAINTENANCE )

The targets and features of TPM

TPM target is to maximize the efficient usage of the machine during the whole lifecycle.
The operation of TPM needs the involvement of all organization units at all level.
This motivates the teamwork and the autonomous activity.
TPM includes the improvement of the operational/maintenance system,
the implementation of the good housekeeping, the improvement of
the problem solving ability to be achieve the ZERO breakdown, ZERO Accident,
ZERO defect.
Top management should prepare an evaluation system.
Based on the evaluation system the ability and responsibility of
the employee should be appreciated and/or rewarded.

TPM Third Country TC-print

SUPPLEMENTATION OF THE CONVENTIONAL MAINTENANCE

Requirements for the company: high level Production & Quality

Multi qualification
Creativity
Changing job

Requirements for the employees

Conventional maintenance
Operator

= Operates the
machine

Maintenance = Maintenance
+
person
repair
Engineer

+
+

Quality knowledge

Maintenance planning
Planning for easy
maintenance

= Production
cycle

Daily checking
Observe the abnormality
Cleaning and lubrication

planning

TPM Third Country TC-print

T
= P
M

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THE SIX BIG LOSSES REDUCE THE EFFICIENCY

1! BREAKDOWN
2! SET UP & ADJUSTMENT
3! SPEED LOSS
4! SHORT STOPS, IDELING
5! START UP LOSS
6! DEFECT & REWORK

TPM Third Country TC-print

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THE 6 BIG LOSSES AND OEE AS THE MAIN INDICATOR

Overall Equipment Efficiency (OEE)

Theoretical available planned time
Planned
downtime

Loading hours
Downtime
loss

Utilization hours
Net utilization hours
Value added
hours

Defect
loss

Speed
loss

Training,
Events
1. Breakdown
2. Set up, adjustment

3. Short stops / Idling loss

4. Reduced speed
5. Quality loss
6. Start-up

Loading hours Downtime Standard cycle time x Processed unit Processed unit Def. u
X
X
Processed units
Utilization hours
Loading hours
AVAILIBILITY

PERFORMANCE RATE

TPM Third Country TC-print

QUALITY RATE

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THE 5 COUSES OF BREAKDOWNS

Machine basic
poor condition

Lack of
skill

Poor operation
conditions

Poor
Design

Lack of restoration
of deterioration

TPM Third Country TC-print

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BREAKDOWN PREVENTION

1. GUARANTEE THE BASIC CONDITIONS:

-

MACHINE CLEANING

AT THE SOURCE OF THE DIRT

TIGHTENING

FIX LOOSENING

OILING

FILLED VOLUME LIST

STANDARDS

CLEANING & LUBRICATION

TPM Third Country TC-print

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BREAKDOWN PREVENTION
2. KEEPING THE OPERATION CONDITIONS
-

DEFINE THE PLANNED CAPACITY AND THE LOAD LIMIT

OPERATION METHOD STANDARDIZATION

DEFINITION AND IMPROVEMENT OF

THE USAGE CONDITIONS OF THE PARTS & UNITS

DEFINITION OF THE PIPES & CABLES

IMPROVEMENT OF THE IMPLEMENTATION INSTRUCTIONS

PROTECTION AGAINST DUST AND WATER

AT THE SLIDING & TURNING PARTS

GUARANTEE THE ENVIRONMENTAL CONDITIONS IN TERMS

OF DUST, TEMPERATURE, HUMADITY AND VIBRATION

TPM Third Country TC-print

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BREAKDOWN PREVENTION

3. RESTORE THE DETERIORATION

-

BIG CHANGES ARE RECOGNISED SMALL CHANGES (DETERIORATION)

SOMETIMES ARE OVERLOOKED BUT CAN MAKE
SPORADIC BREAKDOWNS

DETERIORATION SHOULD BE MONITORED

THE NEGLECTED ACTIONS MUST BE DONE

TPM Third Country TC-print

CLEANING, OILING

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BREAKDOWN PREVENTION

4. IMPROVE THE MAINTENANCE

-

ANALIZE THE BREAKDOWNS

ESTABLISH A PREVENTIVE MAINTENANCE SYSTEM

DEFINE STANDARDS FOR THE MAINTENANCE ACTIVITY

TRAIN THE MAINENANCE STAFF AND OPERATORS

TPM Third Country TC-print

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BREAKDOWN PREVENTION
5. IMPROVE THE CONSTRUCTION
-

IF THE RESTORATION IS NOT ABLE TO REDUCE THE FAILURES TO ZERO

AND MAINTENANCE COST WILL INCREASE, IT IS NECESSARY TO
CHANGE THE MACHINE DESIGN

STEPS OF THE DESIGN CHANGING:

- UNDERSTAND THE STATE OF THE MACHINE BEFORE AND AFTER
FAILURE
- STUDY THE STRUCTURE AND THE FUNCTION OF THE MACHINE
- BE SURE THAT ALL OF THE DESIRED CONDITIONS WERE
IMPLEMENTED ON A PROPERLY WAY
- ANALYSE THE CAUSES
- DEVELOPE AN IMPROVEMENT PLAN
- IMPLEMENT THE PLAN AND MONITOR THE RESULT

TPM Third Country TC-print

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BREAKDOWNS AND RELIABILITY

MTBF indicator

Mean Time Between Failures

MTBF =

TBF1 + TBF2
2

t7

t8

MTTR =

TTR1 + TTR2
2

Performance
TBF1

TBF2

Working

DT Downtime

Stoping
t1

t2 t3

t4

t5

TTR1

Time

TTR2
DT2

DT1

MTTR indicator

t6

Mean Time To Repair

TPM Third Country TC-print

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POINTS OF THE QUICK RESTORATION (After a breakdown occurs)

} Information flow

} Parts store

Arrangement
Indication

} Parts suppliers, service contracts

Downtime

Placement

Organization

} Parts reserve

Placement

} Storing of the repair tools

Arrangement

TTR

Indication

} Skills training

TPM Third Country TC-print

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DEPLOYMENT
PROFIT - PRODUCTIVITY - EFFICIENCY
Breakdown
Set up, adjust
Short stop
Reduced speed
Quality loss
Start up loss

OEE

Availability rate

Indicators for
the six big losses

Performance rate

4
5

x
6 Quality rate

Loss analysis

Length

Frequency
occurrence/week

1. Machine basic poor condition

2. Poor operation conditions
3. Lack of restoration of deterioration
4. Poor design
5. Lack of skill
Operational failure

Analyze
the 5 main
causes of
the machine
breakdown

B
R
E
A
K
D
O
W
N

min/occurrence

Analyze
the cause of
the long
repair time

1.Spare part
2.Organiz.
3.Tools
4.Training

Maintenance failure

TPM Third Country TC-print

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TPM Third Country TC-print

Initial Phase Manageement

Skill Development

Planned Maintenance

Continuous Improvement

Autonomous Manageement

TOTAL PRODUCTIVE
MAINTENANCE

MANAGEMENT PILLARS

TPM

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