Total Productive Maintenance
Total Productive Maintenance
Total Productive Maintenance
Presented by Anchal Rai, Dhruv Sharma, Nitish Kumar and Pratik Gupta DFT-7 Batch 2010-14
Design Deficiency
Breakdown Maintenance
Planned
Unplanned
OVERVIEW
A company-wide system developed to maintain, monitor, and improve all capital assets of a company. For production it is a system that maximizes equipment effectiveness and maintains product flow.
Production costs
Effectiveness of manufacturing cells or flow lines
TPM = Total Productive Maintenance Proactive (with all employees involved) Preventive Predictive Planned
CAUSES OF WASTE
Excess Manning
Poor layout and material presentation Rework and extra processes Inconsistent / inefficient work methods
Excess Downtime
Process not compatible with customer expectations or design spec (design for mfg) Tooling condition Operator methods and errors
CAUSES OF WASTE
Excess Manning
Poor layout and material presentation Rework and extra processes Inconsistent / inefficient work methods
Excess Downtime
Process not compatible with customer expectations or design spec (design for mfg) Tooling condition Operator methods and errors
7 WASTES
Transportation Excess production Added processes Motion Waiting Inventory Non-conformance (defectives)
LEAN SYSTEM
Peak Performance Pull system / flow production
5S
Visual Factory
TPM
Standardized Work
THE WAY
1. Starts with 5S / Visual Factory 2. Builds a comprehensive Downtime Database by cause, frequency, and duration 3. Predicts and prevents downtime by PM system 4. Expands role of Operator as first point of early warning and prevention 5. Develops Professional Maintenance skills
THE WAY
1. 5S/Visual Factory
Visual Factory
Downtime Visual Controls
2. Downtime Database
Categorize at a minimum by Equipment, Tooling, C/O, Other Segmented bar graph for E-T-O lost time
Downtime Tracking
THE WAY
History of downtime a. Downtime measurement & tracking b. Mean Time Between Failures c. Average downtime d. Cause and effect analysis e. Cost to maintain Develop Preventive Maintenance schedules based on frequency of failure and magnitude of average lost time
4. First point of early warning and detection
One point lessons for operator awareness o Creates OMP (Operator - Maintenance Partnership)
THE WAY
5. Professional Maintenance
Equip Safety
Skill building
Cross-training Maintenance Management System Down alarms
THE WAY
5. Professional Maintenance
Production Operators Clean & Check Observe Categorize Production Planning & Control Schedule P.M.
1. 2. 3.
4.
5. 6.
Speed
Quality defects and rework Start-up (loss of yield)
QUANTIFICATION
QUANTIFICATION
Operation time (Scheduled time available Downtime) Availability = ______________________________________________ x 100 Scheduled time available
processed amount x ideal cycle time Performance rate = _____________________________ Operation time
Quality rate =
SHIFT IN ATTITUDES
Operator
Maintenance
Operator
Maintenance
I use
We maintain
Conventional
TPM