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Manger
Meeting Agenda
I. II. Understanding Downtime -Group Major Losses of TPM -Antoinette Lockett
I. II. III. IV. Planned Downtime Losses -Xiaoyan Liu Unplanned Downtime Losses -Laura Dietrich Reduce Speed LossesPoor Quality Losses -Waseem Manzoor What is TPM -Antoinette Lockett Breakdown of TPM -Laura Dietrich TPM History -Laura Dietrich TPM Evolution Goal of TPM -Antoinette Lockett Three Principles of Prevention
III.
II. III.
IV.
Understanding
Downtime
MAJOR LOSSES
TPM
Breakdown of TPM
TOTAL = All encompassing by maintenance and production individuals working together PRODUCTIVE = Production goods and services that meet or exceed customers expectations MAINTENANCE = Keeping equipment and plant in as good as or better than the original conditions at all times
TPM - History
Productive maintenance (PM) originated in the U.S. in late 1940s & early 1950s Japanese companies modified and enhanced it to fit the Japanese industrial environment The first use the term TPM was in 1961 by Nippondenso, a Japanese auto components manufacturer Seiichi Nakajima head of JIPM, one of the earliest proponents, known as the Father of TPM
TPM - Evolution
Breakdown maintenance Preventive maintenance (PM) Productive maintenance Total productive maintenance
Goals of TPM
1. Aims at getting the most effective use of equipment 2. Builds a comprehensive PM system 3. Brings together people from all departments concerned with equipment 4. Requires the support and cooperation of everyone from top managers down 5. Promotes and implements PM activities based on autonomous small group activities. 6. Maintaining Equipment for life 7. Encouraging input from all employees 8. Using teams for continuous improvement
TPM 8 PILLARS
PILLARS OF TPM
5s
Training
Office TPM
OEE
What is OEE
OEE (overall equipment efficiency) is a best practices way to monitor and improve the efficiency of your manufacturing processes
machines manufacturing cells assembly lines
OEE Factors
Plant Operating Time Planned production time
planned downtime ie. breaks
Availability
downtime losses
Performance
Speed losses
Quality
Quality losses
Calculating OEE
Availability = Operating time/planned production Performance = Ideal Cycle Time / Total Pieces or
Quality = Good Pieces / Total Pieces OEE = Availability X Performance X Quality
Availability =
Performance =
OEE =
Availability X Performance X Quality
= 0.8881 X 0.8611 X 0.9780 = 0.7479 (74.79%)
TPM BENIFITS
TPM - Benefits
Improved equipment eliminates the root cause of defects Defects are prevented through planned maintenance Preventive maintenance costs are reduced as equipment operators conduct autonomous maintenance Improved equipment designs ensure that new equipment naturally produces fewer defects Simplified products designs and a redesigned process produce with few defects Engineers, technicians and managers are trained in maintenance and quality
TPM - Benefits
(Japanese TPM Prize winners during 19821984) Equipment failures reduced from 1,000/month to 20/month Quality defects reduced from 1.0% to 0.1% Warranty claims reduced by 25% Maintenance costs reduced by 30% WIP decreased by 50% Productivity improved by 50%. (Patterson & Fredendall, 1995)