Vous êtes sur la page 1sur 38

ARE 524

Facilities Maintenance Management


December 13th , 2003
COLLEGE OF ENVIRONMENTAL DESIGN

Total
Total Productive
Productive Maintenance
Maintenance
Section
Section 88
Uptime
Uptime
Strategies
Strategies for
for Excellence
Excellence in
in
Maintenance
Maintenance Management
Management
By:
By: John
John Dixon
Dixon Campbell
Campbell

Prepared By: Instructor


KAMAL A. BOGES # 210321 Dr. ABDULMOHSEN AL-HAMMAD
COLLEGE OF ENVIRONMENTAL DESIGN

Quantum
Leaps
Process
Reengineering

Continuous
Improvement
RCM TPM

Data Plan and Control


Measures Tactics
Management Schedule

Strategy Management Leadership

World Class Maintenance


2
OUTLINE
OUTLINE

 INTRODUCTION
INTRODUCTION
COLLEGE OF ENVIRONMENTAL DESIGN


 OBJECTIVES
OBJECTIVES AND
AND THEMS
THEMS OF
OF TPM
TPM
ASSET
 ASSET STRATEGY
STRATEGY
EMOWERMENT
 EMOWERMENT
RESOURCE
 RESOURCE PLANNING
PLANNING AND
AND SCHEDULING
SCHEDULING
SYSTEM
 SYSTEM AND
AND PROCEDURES
PROCEDURES
MEASUREMENT
 MEASUREMENT
CONTINOUS
 CONTINOUS IMPROVEMENT
IMPROVEMENT
PROCESSES
 PROCESSES
 IMPLEMENTING
 IMPLEMENTING TPM:
TPM: THE
THE ELEMENTS
ELEMENTS
AWARENESS,
 AWARENESS, EDUCATION,
EDUCATION, AND
AND TRAINING
TRAINING
 KEY
 KEY SUCCESS
SUCCESS FACTORS
FACTORS

3
INTRODUCTION
INTRODUCTION
 Total
 Total Productive
Productive Maintenance
Maintenance (TPM)
(TPM) isis an
an
COLLEGE OF ENVIRONMENTAL DESIGN

approach
approach toto managing
managing physical
physical assets
assets that
that
emphasizes
emphasizes thethe importance
importance of of operator
operator
involvement
involvement in in making
making equipment
equipment reliable
reliable
 Management
 Management has has always
always held
held an
an operator
operator
accountable
accountable for
for production
production output.
output. More
More than
than ever,
ever,
that
that person
person is
is also
also responsible
responsible nownow for
for product
product
quality
quality
 Many
 Many factors
factors affect
affect how
how well
well that
that can
can be
be achieved,
achieved,
including
including the
the way
way in
in which
which the
the workplace
workplace is is
organized
organized asas well
well as
as the
the equipment’s
equipment’s
effectiveness.
effectiveness. When
When several
several people
people are
are involved,
involved,
producing
producing quality
quality depends
depends on on teamwork
teamwork
4
TPM
TPM PRINCIPLES
PRINCIPLES -- 1/4
1/4
 In
 In its
its broadest
broadest sense,
sense, TPM
TPM is
is based
based on
on three
three sets
sets of
of
COLLEGE OF ENVIRONMENTAL DESIGN

principles
principles
1.
1. Maintenance
Maintenance Engineering
Engineering;; Seeks
Seeks toto manage
manage the the
equipment
equipment life
life cycle,
cycle, from
from strategic
strategic asset
asset planning,
planning,
through
through design
design andand construction,
construction, to to operation,
operation,
maintenance,
maintenance, and and disposal.
disposal. Several
Several techniques
techniques
characterize
characterize the
the proactive
proactive nature
nature ofof maintenance
maintenance
engineering
engineering including:
including:
 Preventive
 Preventive (or
(or planned)
planned) maintenance:
maintenance: Planned
Planned and
and
scheduled
scheduled maintenance
maintenance activities
activities to
to find
find and
and correct
correct
problems
problems that
that could
could lead
lead to
to failure
failure
 Predictive
 Predictive and
and condition-based
condition-based maintenance:
maintenance: Reducing
Reducing
fixed-time
fixed-time maintenance
maintenance and and relying
relying on
on the
the condition
condition ofof
equipment
equipment toto determine
determine maintenance
maintenance activity
activity

5
TPM
TPM PRINCIPLES
PRINCIPLES -- 2/4
2/4
1.
1. Maintenance
Maintenance Engineering
Engineering;; Cont.
Cont.
COLLEGE OF ENVIRONMENTAL DESIGN


 Productive
Productive (or(or proactive)
proactive) maintenance
maintenance and and cost
cost
reduction:
reduction: Maximizing
Maximizing equipment
equipment performance
performance
through
through reliability
reliability and
and maintainability
maintainability improvement
improvement
and
and failure
failure analysis
analysis

 Equipment
Equipment datadata management:
management: Equipment
Equipment
configuration,
configuration, bills
bills of
of material,
material, as-built
as-built engineering
engineering
drawings
drawings and
and maintenance
maintenance histories
histories

 Life
Life cycle
cycle costing:
costing: TheThe complete
complete cost
cost of
of equipment,
equipment,
from
from design
design and
and specification
specification through
through construction
construction
and
and procurement
procurement to to operations,
operations, maintenance,
maintenance, and
and
disposal
disposal

6
TPM
TPM PRINCIPLES
PRINCIPLES -- 3/4
3/4
2.
2. Total
Total Quality
Quality Management
Management (TQM)(TQM)
COLLEGE OF ENVIRONMENTAL DESIGN


 TQM
TQM concepts
concepts were
were developed
developed after
after WWII
WWII and
and adopted
adopted by by
Japanese
Japanese manufacturing
manufacturing to to improve
improve the
the global
global image
image andand
acceptance
acceptance ofof their
their products
products

 Incremental
Incremental improvements
improvements in in product
product quality
quality at
at each
each stage
stage ofof
the
the process.
process. Therefore
Therefore small
small groups
groups ofof employee
employee use use problem
problem
identification
identification and
and problem
problem solving
solving tools
tools and
and techniques
techniques to to
provide
provide aa higher
higher quality
quality service
service oror product
product to
to their
their customer
customer

 The
The ultimate
ultimate goal
goal of
of TQM
TQM isis zero
zero defects.
defects. Management
Management style style in
in
aa TQM
TQM culture
culture is
is participative,
participative, trusting,
trusting, and
and focused
focused on on fixing
fixing
problems
problems and
and defects,
defects, not
not on
on apportioning
apportioning blame
blame

 Information
Information isis widely
widely shared,
shared, and
and TQM
TQM people
people let
let the
the data
data lead
lead
them
them

7
TPM
TPM PRINCIPLES
PRINCIPLES -- 4/4
4/4
3.
3. Just-in-time
Just-in-time (JIT)
(JIT)
COLLEGE OF ENVIRONMENTAL DESIGN


 JIT
JIT has
has as
as its
its goal
goal the
the elimination
elimination of of all
all waste:
waste: wasted
wasted
time,
time, space,
space, labor,
labor, materials,
materials, inventory,
inventory, movement.
movement. AnyAny
thing
thing that
that does
does notnot add
add value
value in in the
the eyes
eyes ofof the
the
customer
customer adds
adds waste.
waste.

 The
The core
core concept
concept forfor JIT
JIT is
is the
the reduction
reduction ofof the
the cycle
cycle
time.
time. Focusing
Focusing on on time
time to
to process
process and and reducing
reducing this
this
time
time has
has the
the effect
effect of
of reducing
reducing inventory,
inventory, delays,
delays, labor
labor
and
and space
space

 Producers
Producers are are optimized,
optimized, standardized,
standardized, and and taught
taught

 Lot
Lot sizes
sizes are
are reduced
reduced

 Flexibility
Flexibility are
are dramatically
dramatically increased
increased

8
MORE
MORE ABOUT
ABOUT TPM
TPM –– 1/2
1/2
 TPM
 TPM began
began in in Japan
Japan as as aa vital
vital and
and necessary
necessary response
response to to
COLLEGE OF ENVIRONMENTAL DESIGN

business
business imperatives
imperatives to to reduce
reduce waste,
waste, product
product variation,
variation,
and
and production
production cyclecycle time
time
 ItIt was
 was aa fresh
fresh approach
approach to to the
the new
new challenges
challenges of of the
the
marketplace,
marketplace, not not aa logical
logical progression
progression of of systematic
systematic
maintenance
maintenance management
management
 Just-in-time
 Just-in-time technique,
technique, though,
though, attacked
attacked all
all forms
forms ofof
waste-any
waste-any thing thing that
that did
did not
not add
add value
value to
to the
the
manufacturing
manufacturing processprocess
 Under
 Under these
these circumstances,
circumstances, the the success
success of of the
the entire
entire
process
process relied
relied on
on each
each machine
machine working
working to to aa uniform
uniform plant
plant
load,
load, drumbeat.
drumbeat.
 To
 To further
further complicate
complicate matters
matters forfor maintenance,
maintenance, finalfinal
quality
quality control
control inspection
inspection was was being
being moved
moved upstream
upstream in in
process,
process, to to eliminate
eliminate defects
defects andand yield
yield fluctuation
fluctuation at at their
their
source.
source. As As aa result,
result, machine
machine performance
performance problems
problems werewere
being
being identified
identified much
much earlier
earlier
9
MORE
MORE ABOUT
ABOUT TPM
TPM –– 2/2
2/2

 Demands
 Demands for for conformance
conformance andand reliability
reliability were
were
COLLEGE OF ENVIRONMENTAL DESIGN

greatly
greatly increased,
increased, with
with more
more stringent
stringent variation
variation
checks
checks
 Maintenance
 Maintenance management-
management- or,or, more
more correctly,
correctly, the
the
management
management of of equipment
equipment effectiveness-
effectiveness- hadhad to
to
adapt
adapt quickly
quickly thethe new
new directives
directives
 The
 The concept
concept thatthat evolved
evolved was
was TPM,
TPM, sometimes
sometimes
known
known byby its
its most
most prominent
prominent feature,
feature, autonomous
autonomous
(operator)
(operator) maintenance
maintenance

10
OBJECTIVES
OBJECTIVES AND
AND THEMS
THEMS OF
OF TPM
TPM –– 1/11
1/11

 The
 The prime
prime objectives
objectives of
of TPM
TPM are
are to:
to:
COLLEGE OF ENVIRONMENTAL DESIGN

 Maximize
 Maximize equipment
equipment effectiveness
effectiveness and
and productivity
productivity and
and
eliminate
eliminate all
all machine
machine losses
losses
 Create
 Create aa sense
sense ofof ownership
ownership inin equipment
equipment operators
operators
through
through aa program
program ofof training
training and
and involvement
involvement
 Promote
 Promote continuous
continuous improvement
improvement through
through small-group
small-group
activities
activities involving
involving production,
production, engineering,
engineering, and
and
maintenance
maintenance personnel
personnel
 Each
 Each enterprise
enterprise has
has its
its own
own unique
unique definition
definition and
and
vision
vision for
for TPM,
TPM, but
but in
in most
most cases
cases there
there are
are
common
common elements
elements in
in any
any TPM
TPM program.
program. These
These have
have
been
been summarized
summarized in in the
the TPM
TPM wheel
wheel in
in Figure
Figure 8-1
8-1

11
OBJECTIVES
OBJECTIVES AND
AND THEMS
THEMS OF
OF TPM
TPM –– 2/11
2/11
Elements
COLLEGE OF ENVIRONMENTAL DESIGN

Asset
Processes
Strategy

Themes
Continuous
• Training
Improvement Empowerment
Team • Decentralization
• Maintenance
prevention
• Multi-skilling
Resources
Measurement Planning and
Scheduling
Systems and
Procedures

Figure 8-1 The TPM Wheel


12
1.
1. Asset
Asset Strategy
Strategy –– 3/11
3/11

 TPM
 TPM is is commonly
commonly usedused to
to support
support and
and enable
enable the
the
COLLEGE OF ENVIRONMENTAL DESIGN

principles
principles of of TIJ
TIJ and
and TQM
TQM
 This
 This usually
usually involves
involves moving
moving some
some equipment
equipment
into
into aa cell
cell arrangement
arrangement andand removing
removing anything
anything
that
that is
is redundant
redundant
 Setup
 Setup modification
modification andand upgrading
upgrading machine
machine
requirements
requirements are are also
also commonly
commonly part
part of
of the
the plan
plan
 Simplifying,
 Simplifying, streaming,
streaming, and
and automating
automating thethe
manufacturing
manufacturing process
process have
have an
an impact
impact on
on the
the way
way
maintenance
maintenance strategy
strategy with
with the
the neww
neww asset
asset
structure
structure
13
1.
1. Asset
Asset Strategy,
Strategy, cont.
cont. –– 4/11
4/11

 When
 When JIT
JIT is
is introduced,
introduced, maintenance
maintenance
COLLEGE OF ENVIRONMENTAL DESIGN

management
management normally
normally should
should involved
involved
immediately:
immediately:
 Layout
 Layout evaluation
evaluation -- including
including maintainability,
maintainability,
operability,
operability, hydraulic/electrical/steam/plumbing
hydraulic/electrical/steam/plumbing
services,
services, environmental
environmental concerns,
concerns, andand floor
floor loading
loading
consideration
consideration
 Equipment
 Equipment modification
modification –– such
such asas solving
solving chronic
chronic
problems
problems before
before aa cell
cell startup.
startup. This
This could
could also
also mean
mean
providing
providing enablers,
enablers, for
for example,
example, reducing
reducing excess
excess
motion
motion to
to reduce
reduce wear
wear and
and noise
noise
 Post-move
 Post-move services
services –– to
to restore
restore the
the equipment
equipment to to
satisfactory
satisfactory operating
operating condition
condition asas aa cell
cell formed.
formed. Of Of
key
key importance
importance isis the
the initiation
initiation or
or revision
revision of of aa specific
specific
preventive
preventive maintenance
maintenance program
program
14
2.
2. Empowerment
Empowerment -- 5/11
5/11

 TPM
 TPM putsputs the
the power
power inin the
the employee’s
employee’s hand.
hand. ItIt
COLLEGE OF ENVIRONMENTAL DESIGN

grants
grants workers
workers autonomy,
autonomy, along
along with
with responsibility
responsibility
 At
 At the
the same
same time
time TPM
TPM recognizes
recognizes that
that employees
employees in in
one
one area
area have
have much
much to
to teach
teach and
and learn
learn from
from others
others
The
The entire
entire organization
organization gains
gains strength
strength and
and ideas
ideas
from
from motivated
motivated continuous
continuous improvement
improvement teams
teams
 A
 A TPM
TPM environment
environment encourages
encourages aa skills
skills between
between
operators
operators and and maintenance,
maintenance, andand multi-skill
multi-skill training
training
in
in the
the various
various crafts
crafts
 ItIt can
 can provide
provide increase
increase job
job satisfaction
satisfaction for
for
operations,
operations, trades,
trades, engineering,
engineering, andand supervision
supervision
alike
alike 15
2.
2. Empowerment,
Empowerment, cont.
cont. -- 6/11
6/11

 Most
 Most exciting
exciting about
about TPMTPM isis that
that itit can
can fundamentally
fundamentally
COLLEGE OF ENVIRONMENTAL DESIGN

change
change organization
organization culture.
culture. Centralized,
Centralized, command
command
and
and control
control maintenance
maintenance structure
structure cannot
cannot support
support aa
JIT/TQM/TPM
JIT/TQM/TPM initiative
initiative
 Operator
 Operator ownership
ownership is is not
not about
about boundaries
boundaries or or
barriers
barriers around
around equipment
equipment or or sections
sections of of the
the
process
process
 It’s
 It’s an
an expression
expression of of commitment
commitment and and caring
caring about
about
condition,
condition, causes,
causes, andand effects
effects
 Building
 Building operator
operator ownership
ownership is is mostly
mostly aa matter
matter of
of
removing
removing impediments
impediments and and providing
providing correct
correct
training
training and
and tools
tools toto encourage
encourage aa supportive
supportive
relationship
relationship that
that is
is technically
technically informed
informed
16
3.
3. Resource
Resource Planning
Planning and
and Scheduling
Scheduling -- 7/11
7/11
 During
 During the the introduction
introduction of of TPM,
TPM, there
there will
will be
be significantly
significantly
COLLEGE OF ENVIRONMENTAL DESIGN

increased
increased demanddemand on on the
the maintenance
maintenance department,
department,
especially
especially as as operator
operator train
train to
to be
be more
more equipment
equipment conscious
conscious
 As
 As theythey discover
discover thethe causes
causes of of chronic
chronic equipment
equipment losses
losses of
of
malfunctions,
malfunctions, they they will
will want
want toto have
have them
them corrected
corrected quickly
quickly
 IfIf these
 these operators
operators areare to
to be
be enthusiastic
enthusiastic partners
partners in
in
equipment
equipment care, care, the
the maintenance
maintenance department
department must must have
have
planning
planning and and scheduling
scheduling procedures
procedures in in place.
place. They
They must
must
have
have the the capacity
capacity andand skills
skills available
available to to assign
assign priorities
priorities and
and
carry
carry out out the
the work
work quickly
quickly and
and professionally
professionally
 As
 As manymany organizations
organizations have have found,
found, itit help
help toto dedicate
dedicate
specific
specific tradespersons
tradespersons to to particular
particular areas
areas
 In
 In this
this way,
way, they
they become
become familiar
familiar with
with thethe equipment
equipment andand
form
form closer
closer ties
ties with
with the
the operators
operators andand supervisors
supervisors

17
44 Systems
Systems and
and Procedures
Procedures -- 8/11
8/11
 As
 As continuous
continuous improvement
improvement teams teams begin
begin to
to focus
focus onon
COLLEGE OF ENVIRONMENTAL DESIGN

equipment
equipment performance,
performance, standards
standards best best practice
practice operating
operating
and
and maintenance
maintenance procedures
procedures will will evolve
evolve
 ItIt will
 will quickly
quickly become
become dailydaily routine
routine to to track
track information
information
such
such as as equipment
equipment histories,
histories, part
part and
and materials,
materials, individual
individual
training
training progression,
progression, and and costs
costs
 Systematic
 Systematic maintenance
maintenance management
management requires requires the
the most
most
effective
effective wayway to
to reduce
reduce or or mitigate
mitigate thethe risk
risk of
of failure
failure
 First,
 First, the
the nature
nature of
of failure
failure in
in aa specific
specific case
case must
must bebe
understood
understood
 Then
 Then the the remedy
remedy cancan bebe chosen,
chosen, whether
whether itit be
be based
based onon
time,
time, useuse or
or condition
condition factors,
factors, or or some
some other
other tactic
tactic

18
5.
5. Measurement
Measurement -- 9/11
9/11
 With
 With continuous
continuous improvement,
improvement, the the current
current reality
reality is
is judged
judged
COLLEGE OF ENVIRONMENTAL DESIGN

against
against aa future
future vision.
vision. In
In maintenance
maintenance management,
management, the the
prime
prime objective
objective is is asset
asset productivity:
productivity: asset
asset output
output divided
divided
by
by all
all inputs
inputs
 FOR
 FOR TPM,
TPM, itit is
is also
also useful
useful to
to measure
measure continuous
continuous
improvement
improvement success,success, including
including the
the number
number of of active
active
teams
teams andand their
their individual
individual and
and collective
collective progress
progress
 The
 The future
future vision
vision is is best
best tempered
tempered with
with anan understanding
understanding
of
of what
what the
the competition,
competition, industry
industry at
at large,
large, or
or best-in-class
best-in-class
have
have achieved.
achieved. Benchmarking
Benchmarking is is useful
useful inin this
this regard
regard

19
6.
6. Continuous
Continuous Improvement
Improvement Team
Team -- 10/11
10/11
 Continuous
 Continuous improvement,
improvement, based based onon Kaizen
Kaizen principles
principles in in Japan,
Japan,
COLLEGE OF ENVIRONMENTAL DESIGN

is
is central
central toto TQM
TQM and
and JIT
JIT
 Organizations
 Organizations that that have
have begun
begun implementing
implementing TQM, TQM, JIT,
JIT, or
or
Continuous
Continuous Improvement
Improvement (CI) (CI) processes
processes will will have
have CICI team
team inin
place
place
 TPM
 TPM team
team tends
tends toto base
base their
their agenda
agenda on on effective
effective maintenance
maintenance
management
management information
information system
system (for
(for example,
example, equipment
equipment
histories
histories for
for failure
failure analysis).
analysis). This
This begins
begins with
with aa Pareto
Pareto review
review
of
of failure
failure of
of the
the equipment
equipment or or processes
processes thatthat govern
govern
bottlenecking
bottlenecking or or add
add the
the most
most value
value to
to the
the product
product flowflow
 Operators
 Operators in in TPM
TPM build
build aa strong
strong relationship
relationship withwith their
their
equipment.
equipment. TheyThey drive
drive an
an understanding
understanding withinwithin teams
teams of of failure
failure
causes,
causes, effects
effects and
and impacts,
impacts, and
and the
the resulting
resulting actions
actions to to
eliminate
eliminate these
these failure
failure

20
7.
7. Processes
Processes –– 11/11
11/11

 TPM
 TPM isis often
often aa radical
radical change
change in
in the
the way
way asset
asset
COLLEGE OF ENVIRONMENTAL DESIGN

maintenance
maintenance is is managed
managed
 Some
 Some of of the
the traditional
traditional processes
processes forfor preventive,
preventive,
corrective,
corrective, oror breakdown
breakdown maintenance
maintenance and and for
for stores
stores
inventory
inventory control
control are
are simply
simply no
no longer
longer appropriate
appropriate
 In
 In the
the new
new climate
climate ofof responsiveness,
responsiveness, flexibility,
flexibility, and
and
empowerment,
empowerment, the the existing
existing processes
processes mustmust bebe revisited.
revisited.
They
They must
must bebe clearly
clearly understood,
understood, analyzed,
analyzed, and
and then
then
redesigned
redesigned to to support
support thethe TPM
TPM objectives
objectives
 Each
 Each step
step along
along the
the way
way must
must add
add value
value and
and minimize
minimize
any
any waste
waste inin cost,
cost, time,
time, service,
service, quality,
quality, or
or other
other
resources
resources

21
IMPLEMENTING
IMPLEMENTING TPM:
TPM: THE
THE ELEMENTS
ELEMENTS –– 1/12
1/12

 What
 What TPM
TPM means,
means, and and what
what itit will
will accomplish,
accomplish, is is different
different
COLLEGE OF ENVIRONMENTAL DESIGN

for
for each
each application.
application. The The implementation
implementation plan, plan, too,
too, needs
needs
to
to be
be specific
specific to to the
the situation
situation and and plant
plant environment
environment
 A
 A small
small wood-working
wood-working firm firm with
with aa tradition
tradition of
of production-
production-
maintenance
maintenance integration
integration could
could take
take aa more
more informal
informal
approach
approach than
than aa large
large integrated
integrated steel
steel mile
mile
 A
 A basic
basic methodology
methodology that that has
has proved
proved successfully
successfully as as aa
guide
guide in
in many
many diverse
diverse applications
applications is is presented
presented in in Figure
Figure
8-2
8-2
 Following
 Following an an implementation
implementation plan plan adapted
adapted from
from thethe Japan
Japan
Institute
Institute of
of Plant
Plant Maintenance,
Maintenance, the the enterprise
enterprise should
should
progress
progress through
through four four phases
phases in in charting
charting in
in its
its new
new course
course

22
IMPLEMENTING
IMPLEMENTING TPM:
TPM: THE
THE ELEMENTS
ELEMENTS ,, cont.
cont. –– 2/12
2/12
I. Stabilize Mean Time Between II Lengthen Equipt. Life III. Periodically Restore IV. Predict Equipment Life
Failure Deterioration
COLLEGE OF ENVIRONMENTAL DESIGN

Equipment Restore accelerated deterioration Learn more about Conduct autonomous Manage operations and
Improvement by cleaning, lubricating, and equipment mechanisms inspections and adjustments: daily equipment care and
tightening, and correcting visible and functions: develop organize and visually manage inspections autonomously:
defects inspection skills work area carry out simple repairs and
replacement

Equipment Prevent accelerated deterioration • Correct design and fabrication weaknesses • Further extend life using
Improvement with improvement to: • Prevent operating and repair errors new materials and
• Control contamination sources • Eliminate sporadic failures technologies
•Enhance accessibility for cleaning, • Learn and apply advanced
• Improve maintainability and operability
lube, and inspection failure analysis techniques
Address chronic equipment losses
and prevent recurrence

Planned • Prepare equipment logs • Rank failures prioritize • Estimate life spans and • Apply condition-based
Maintenance • Help operators establish daily PM work learn early signs of internal monitoring technique to
inspection and • Standardize routine deteriorating predict life
• Introduce visual control maintenance activities • Set standards fro periodic • Conduct periodic
• Clarify operating conditions; • Create data management inspection and parts restoration based on
systems to monitor replacement periodic life
comply with conditions of use
failures, equipment, • Improve efficiency of
spares, costs planned inspection and
maintenance work and
improve control of data and
spares

23
Figure 8-2 TPM Implementation
IMPLEMENTING
IMPLEMENTING TPM:
TPM: THE
THE ELEMENTS,
ELEMENTS, cont.
cont. –– 3/12
3/12
I. Stabilize Mean Time Between II Lengthen Equipt. Life III. Periodically Restore IV. Predict Equipment Life
Failure Deterioration
Quality Clarify relationship between quality and equipment, people, Establish and maintain • Build in QM controls at
COLLEGE OF ENVIRONMENTAL DESIGN

Maintenance materials, methods equipment control conditions the design stage

Maintenance Define data system requirements Incorporate data from current equipment improvement in
Prevention and begin documenting new equipment design specifications
equipment improvements

Figure 8-2 TPM Implementation

24
IMPLEMENTING
IMPLEMENTING TPM:
TPM: THE
THE ELEMENTS,
ELEMENTS, cont.
cont. –– 4/12
4/12

 This
 This route
route progresses
progresses from
from stabilizing
stabilizing the
the mean
mean
COLLEGE OF ENVIRONMENTAL DESIGN

time
time between
between failures
failures and
and extending
extending equipment
equipment
life
life to
to predicting
predicting equipment
equipment life
life through
through condition
condition
monitoring
monitoring
 The
 The four
four phases
phases ofof activities
activities are
are conducted
conducted by
by
team
team of of production,
production, maintenance,
maintenance, and and engineering
engineering
personnel
personnel working
working inin concert
concert
 The
 The entire
entire implementation
implementation process
process isis supported
supported
throughout
throughout by by comprehensive
comprehensive education
education and
and
training
training (see
(see Figure
Figure 8-3)
8-3)

25
IMPLEMENTING
IMPLEMENTING TPM:
TPM: THE
THE ELEMENTS,
ELEMENTS, cont.
cont. –– 5/12
5/12
General Maintenance
COLLEGE OF ENVIRONMENTAL DESIGN

Management Engineer Operators Maintenance


TPM objectives, elements,
themes    
General equipment cleaning,
inspection, monitoring  
Problem identification, analysis
tools   
Basic equipment functioning,
adjustment, optimization of skills  
Focused technical skills

Maintenance prevention and
equipment redesign   
Figure 8-3 TPM Education and Training
26
1.
1. Awareness,
Awareness, Education,
Education, and
and Training
Training –– 6/12
6/12

 Learning
 Learning underscores
underscores each
each element
element of of TPM.
TPM. AtAt
COLLEGE OF ENVIRONMENTAL DESIGN

Nachi
Nachi Fujikoshi
Fujikoshi Corporation
Corporation in in Japan
Japan “Cultivating
“Cultivating
equipment-conscious
equipment-conscious workers
workers is is the
the base
base upon
upon
which
which every
every other
other feature
feature ofof (TPM)
(TPM) rests.
rests.
Education
Education and
and training
training is
is not
not only
only one
one of
of the
the
fundamental
fundamental improvements
improvements activities
activities ofof TPM,
TPM, itit is
is
aa central
central pillar
pillar that
that supports
supports others”
others”
 Managers,
 Managers, maintenance
maintenance staff,
staff, team
team leaders,
leaders, and
and
equipment
equipment operators
operators all
all must
must be be extensively
extensively
involved
involved in
in the
the learning
learning process
process

27
1.
1. Awareness,
Awareness, Education,
Education, and
and Training,
Training, cont.
cont. –– 7/12
7/12

 Training
 Training supports:
supports:
COLLEGE OF ENVIRONMENTAL DESIGN

 Decentralization
Decentralization of of decision-making
decision-making and and
empowerment
empowerment of of employees.
employees. This
This will
will help
help them
them
act
act autonomously,
autonomously, with with knowledge
knowledge andand confidence,
confidence,
and
and asas team
team players
players who
who know
know where
where and
and when
when to
to
ask
ask for
for help
help
 Maintenance
Maintenance prevention
prevention,, or
or minimizing
minimizing the
the amount
amount
of
of maintenance
maintenance intervention
intervention without
without scarifying
scarifying
reliability.
reliability. This
This is
is accomplished
accomplished withwith standard
standard
operating
operating procedures
procedures andand systematic
systematic analysis
analysis and
and
treatment
treatment of of equipment
equipment failures
failures and
and other
other
abnormalities
abnormalities
28
1.
1. Awareness,
Awareness, Education,
Education, and
and Training,
Training, cont.
cont. –– 8/12
8/12
 The
 The use
use of
of tools
tools and
and techniques
techniques for for problem
problem identification,
identification,
COLLEGE OF ENVIRONMENTAL DESIGN

definition,
definition, solution,
solution, and and team
team decision
decision making
making are
are shown
shown in
in
Figure
Figure 8-4
8-4
 These
 These aids
aids are
are invaluable
invaluable for for the
the learning
learning process
process
 Beyond
 Beyond understanding
understanding the the theory
theory behind
behind TPM,
TPM, you
you must
must
have
have some
some practical
practical knowledge
knowledge beforebefore making
making sweeping
sweeping
changes
changes to to the
the system
system
A
 A pilot
pilot project
project inin an
an area
area ofof the
the plant
plant will
will work
work out
out any
any kinks
kinks
and
and build
build experience
experience and and confidence
confidence in in implementation
implementation
team
team
 Of
 Of great
great help
help inin aa trial
trial run
run is
is aa detailed
detailed before-after
before-after study.
study.
One
One effective
effective method
method is is to
to have
have aa staff
staff photograph
photograph or or
videotape
videotape the
the area,
area, looking
looking for for defects,
defects, disorders,
disorders, and
and
deterioration
deterioration
 Such
 Such varied
varied industries
industries as
as aluminum
aluminum rolling,
rolling, primary
primary
steel,
steel, and
and discrete
discrete manufacturing
manufacturing level
level found
found that
that aa
series
series of
of pictures
pictures is
is worth
worth countless
countless words
words ofof
description
description 29
1.
1. Awareness,
Awareness, Education,
Education, and
and Training,
Training, cont.
cont. –– 9/12
9/12
For Problem Definition For Solution Development For Team Decision-making
• Process flowcharting • Customer surveys • Consequences seeking
COLLEGE OF ENVIRONMENTAL DESIGN

• Histograms •Cause and effect diagrams • Brainstorming


• Plan charts • Benchmarking • Normal group technique
• Tree diagrams • Force field analysis • Multivoting
• Pareto diagrams • FMECA • Pairwise ranking
• Statistical process control • Fault tree analysis • Weighted factor evaluation

• Scatter plots • P-M analysis


• Failure Analysis
Automated Tools
• Computer aided design and drafting
• Computer aided manufacturing
• Computerize maintenance management system
• Material management system
• Materials equipment planning
• Computer integrated manufacturing

• Simulation
• Expert systems
• Geographic information management system

Figure 8-4 Tools and Techniques for TPM 30


1.
1. Awareness,
Awareness, Education,
Education, and
and Training,
Training, cont.
cont. –– 10/12
10/12

 Keeping
 Keeping aa visual
visual record
record is
is part
part of
of the
the following
following eight-step
eight-step
COLLEGE OF ENVIRONMENTAL DESIGN

approach
approach of
of piloting:
piloting:
1.
1. Education
Education (basis)
(basis) –– Companywide
Companywide seminarseminar on on the
the elements,
elements,
themes,
themes, and
and objectives
objectives of of TPM,
TPM, and
and how
how itit relates
relates to to TQM,
TQM,
JIT,
JIT, and
and CI
CI programs
programs thatthat already
already inin place
place
2.
2. Survey
Survey –– Determine
Determine whichwhich area
area are
are likely
likely to
to excel
excel in in aa pilot
pilot
program
program because
because of of culture,
culture, attitude,
attitude, preparation,
preparation, or or
management
management stylestyle
3.
3. Selection
Selection –– Select
Select the
the pilot
pilot area
area based
based on on its
its probability
probability of of
success
success and
and onon the
the productivity
productivity improvement
improvement potential.
potential. ItIt
should
should also
also be
be widely
widely applicable
applicable to to other
other areas
areas ofof the
the
operation
operation
4.
4. Data
Data collection
collection –– Carry
Carry out
out Pareto
Pareto analysis
analysis of of the
the frequency
frequency
and
and duration
duration ofof losses
losses caused
caused byby recorded
recorded failures,
failures, setups,
setups,
idling,
idling, minor
minor delays,
delays, quality,
quality, and
and yield
yield losses
losses
31
1.
1. Awareness,
Awareness, Education,
Education, and
and Training,
Training, cont.
cont. –– 11/12
11/12
5.
5. Education
Education (specific)
(specific) –– Present
Present aa detailed
detailed seminar
seminar forfor pilot
pilot
COLLEGE OF ENVIRONMENTAL DESIGN

area
area personnel
personnel describing
describing the the selection
selection process,
process, data
data
analysis
analysis forfor equipment
equipment loses,
loses, and
and TPM
TPM vision
vision
6.
6. Photographic
Photographic tour tour –– Have
Have pilot’s
pilot’s teams
teams taketake “as-is”
“as-is”
photographs
photographs or or videos
videos of of equipment
equipment deterioration,
deterioration, defects,
defects,
disorders,
disorders, housekeeping,
housekeeping, and and so so on,
on, in
in their
their area
area
7.
7. Training
Training –– Relate
Relate the
the Pareto
Pareto analysis
analysis of of losses
losses toto the
the result
result
of
of the
the photographic
photographic tour. tour. Also,
Also, provide
provide training
training toto minimize
minimize
equipment
equipment deterioration
deterioration and and ,, therefore,
therefore, equipment
equipment losses
losses
through
through thethe activities
activities inin Phase
Phase II Stabilize
Stabilize Reliability
Reliability
8.
8. Kickoff
Kickoff –– Choose
Choose aa formal
formal kickoff
kickoff date
date and
and location
location for
for
Phase
Phase I.I. Categorize
Categorize responsibilities
responsibilities for for improvement
improvement for for
production,
production, materials,
materials, maintenance,
maintenance, and and engineering
engineering

32
1.
1. Awareness,
Awareness, Education,
Education, and
and Training,
Training, cont.
cont. –– 12/12
12/12
 ItIt is
 is critical
critical to
to measure
measure the
the progress
progress of
of the
the pilot
pilot program
program to
to
COLLEGE OF ENVIRONMENTAL DESIGN

gain
gain momentum
momentum for for plant
plant wide
wide success.
success. Monitor
Monitor such
such
“outputs”
“outputs” as: as:
 Equipment
Equipment effectiveness
effectiveness –– The
The product
product of
of availability,
availability, the
the
process
process rate,
rate, and
and quality
quality rate
rate
 Reliability
Reliability –– Mean
Mean time
time between
between failure
failure
 Maintainability
Maintainability–– Mean
Mean time
time to
to inspect,
inspect, service,
service, replace,
replace, oror repair
repair
 Also
 Also measure
measure inputs
inputs such
such as
as
 Labor
Labor –– including
including degree
degree ofof PM
PM compliance,
compliance, demonstrated
demonstrated
proficiency
proficiency inin autonomous
autonomous maintenance,
maintenance, crew
crew size,
size, and
and
maintenance
maintenance labor
labor distribution
distribution
 Materials,
Materials, –– including
including engineering
engineering stores
stores inventory
inventory turns,
turns,
inventory
inventory service
service level,
level, vendor
vendor partnering,
partnering, and
and obsolesces
obsolesces
 Cost
Cost effectiveness
effectiveness –– where
where cost
cost are
are measured
measured byby function,
function, area,
area,
equipment,
equipment, job,
job, and
and class
class of
of expense
expense

33
KEY
KEY SUCCESSFUL
SUCCESSFUL FACTOR
FACTOR –– 1/4
1/4

 The
 The single
single mostmost important
important factorfactor to
to implement
implement
COLLEGE OF ENVIRONMENTAL DESIGN

TPM
TPM is is true
true management
management commitmentcommitment
 Organizations
 Organizations with with this
this level
level of of commitment
commitment are are
successful,
successful, even even ifif they
they dodo notnot have
have the
the most
most
comprehensive
comprehensive plan plan or or aa lavish
lavish budget
budget
 What
 What doesdoes honest
honest commitment
commitment mean? mean? You You could
could
say
say it’s
it’s aa little
little like
like bacon
bacon and and eggs
eggs –– the
the chicken
chicken
was
was involved,
involved, but but thethe pig
pig was
was committed
committed
 Management’s
 Management’s commitmentcommitment is is certainly
certainly shown
shown by
by
what
what it’s
it’s willing
willing to to put
put on
on thethe line
line
 The
 The resources
resources allocated
allocated are are important,
important, of of course.
course.
But
But counts
counts even even more more are
are thethe time
time and
and visible
visible
involvement
involvement of of senior
senior management,
management, for for however
however
long
long itit takes
takes to to put
put TPM
TPM in in place
place
34
KEY
KEY SUCCESSFUL
SUCCESSFUL FACTOR
FACTOR –– 2/4
2/4

Other
 Other key
key success
success factors
factors include:
include:
COLLEGE OF ENVIRONMENTAL DESIGN

 The
The team
team approach
approach throughout
throughout the the project
project cycle
cycle
 The
The enthusiasm
enthusiasm and
and team-team
team-team building
building skills
skills of
of
TPM
TPM leaders
leaders or
or project
project managers
managers
 A
A clearly
clearly defined
defined methodology
methodology
 The
The learning
learning processes,
processes, particularly
particularly the
the
communication
communication between
between maintenance
maintenance and and
operations
operations in
in such
such vital
vital areas
areas asas how
how the
the
equipment
equipment does,
does, what
what itit does
does and
and how
how toto keep
keep itit
operating
operating effectively
effectively
 The
The mechanisms
mechanisms in in place
place to to reinforce
reinforce positive
positive
behavior
behavior and
and results
results 35
KEY
KEY SUCCESSFUL
SUCCESSFUL FACTOR
FACTOR –– 3/4
3/4
 Many
 Many ofof North
North America’s
America’s important
important manufacturers
manufacturers and and
COLLEGE OF ENVIRONMENTAL DESIGN

processors
processors are are now
now fully
fully immersed
immersed in in TPM
TPM
 Dupont
 Dupont Fibers
Fibers attributes
attributes major
major gains
gains inin productive
productive capacity
capacity
to
to TPM:
TPM: having
having skilled
skilled people
people getting
getting their
their equipment
equipment up up to
to
as-new
as-new condition
condition and
and keeping
keeping itit there,
there, and
and eliminating
eliminating
failures
failures through
through systematic
systematic improvement
improvement over over thth elong
elong
term
term
 Others
 Others include
include Timkin,
Timkin, Pepsi,
Pepsi, Ford,
Ford, Harley-Davidson,
Harley-Davidson,
Wilson
Wilson Sporting,
Sporting, MACI,
MACI, Saturn
Saturn Corp.,
Corp., Norton,
Norton, John
John Deere,
Deere,
Unilever,
Unilever, Steelcase,
Steelcase, and
and Toyota
Toyota
 But
 But as
as Mark
Mark O’Brein
O’Brein of
of Yamaha
Yamaha said,said, ““ As
As we
we looked
looked
around
around Japan
Japan and
and the
the U.S.
U.S. for
for the
the perfect
perfect TPM
TPM recipe,
recipe, we
we
realized
realized that
that no
no one
one has
has the
the cookbook”
cookbook”
A
 A successful
successful implementation
implementation of of TPM
TPM themes
themes andand elements
elements
certainly
certainly results
results in
in measurable
measurable benefits
benefits
36
KEY
KEY SUCCESSFUL
SUCCESSFUL FACTOR
FACTOR –– 4/4
4/4

Empwered,
 Empwered, motivated
motivated employees
employees will
will contribute
contribute in
in
COLLEGE OF ENVIRONMENTAL DESIGN

significant
significant ways
ways to
to help
help improve
improve asset
asset productivity
productivity
The
 The long-term
long-term benefit
benefit of
of caring
caring about
about maintenance
maintenance
can
can be
be in
in another
another qute
qute from
from Pirsig:
Pirsig:
Each
 Each machine
machine has has its
its own
own personality,
personality, that
that isis the
the real
real
object
object of
of motorcycle
motorcycle maintenance,
maintenance, The The new
new [nachines]
[nachines]
start
start out
out as
as good-looking
good-looking strangers
strangers and, and, depending
depending on on
how
how they
they are
are treated,
treated, degenerate
degenerate rapidly
rapidly into
into bad-acting
bad-acting
grouches
grouches or or even
even cripples,
cripples, or or else
else turn
turn into
into healthy,
healthy,
good-natured,
good-natured, long long lasting
lasting friends.
friends. This
This one,
one, despite
despite the
the
murderous
murderous treatment
treatment itit got
got atat the
the hands
hands of of those
those alleged
alleged
mechanics,
mechanics, seems
seems toto have
have recovered
recovered and and has
has been
been
requiring
requiring fewer
fewer repairs
repairs asas time
time goes
goes onon (Zen
(Zen andand the
the Art
Art
of
of Motorcycle
Motorcycle Maintenance,
Maintenance, P.39) P.39) 37
COLLEGE OF ENVIRONMENTAL DESIGN

Thank You

38