Total Productive MaintenanceTPMLuis Armendariz, P.E. MBA, 6 Lean Systems and Operations ModelingCopyright 20101
Agenda TPM History, Definition, Benefits and Roles Applying TPM, DMAIC & Metrics TPM Success (Benchmark Study in BioTech vs Food & BeverageProcessing Industry) RCA Techniques Current Challenges TMP to Infinity and Beyond Q&ACopyright 20102
TPM HistoryDr. Deming1900-19931951PMNippon DensoPM in 1960Nippon Denso TPM AwardCopyright 20103
Total Productive Maintenance Promote the collaboration between all departments to focus on thedurability of equipmentCopyright 20104
Definition Total: Total employee involvement Productive: Eliminate or minimize breakdown duringproduction Maintenance: Complete a preventive maintenanceprogramCopyright 20105
Benefits of TPM Improves Teamwork Improves Equipment availability Reduces costCopyright 20106
Roles of TPM To target the major causes of poor performance (OEE ) Involve operators in the routine maintenance of their equipment Improve maintenance efficiency Improving skills and knowledge To collaborate in partnership while having a common goalCopyright 20107
Applying TPM Create a cross functional team–––––D-DefineM-MeasureA- AnalyzeI- ImproveC- ControlCopyright 2010 Luis Armendariz8
Define DMAICD: Define the equipment, objectives,success indicators, customers, costCopyright 2010 Luis Armendariz9
Measure 7 Losses DMAICTPM identifies the 7 lossesOEE Availability x Performance x Quality1. Total time available – shutdowns/startup – scheduled maint. - calibration2. Set-UpA3. Initial adjustment time4. Equipment Breakdown Time (TBF, TTR)- unscheduled maint.5. IdlingP6. Speed (cycle time) losses,Q7. Quality losses: start-up and in process qualityCopyright 2010 Luis Armendariz10
OEEDMAICOEE Availability x Performance x QualityAvailability (Downtime Loss) Operating Time / Planned Production TimePerformance (Speed Loss) Ideal Cycle Time / (Operating Time / Total Pieces)Quality (Quality Loss) Good Pieces / Total PiecesOEE FactorShift 1Shift %OEE85.1%86.6%Note: Availability (TBF and TTR)Copyright 201011
OEE “Pharmaceutical vs. Food & Beverage”DMAICOEECopyright 2007 Pharmaceutical Benchmark Study. Informance International. All Rights ReservedCopyright 201012
Equipment Availability : TBF & TTR(Breakdown Time) DMAICtimeSETUPPRODUCEU D UDUDUD UDuring production time, machine is producing(Uptime - green) or not producing (Downtime - red)We define:MTBF Mean time between failuresMTTR Mean time to repairCopyright 201013
TBF-Unscheduled Down Time DMAICMean TBF Line 1 34 hrCopyright 2010 Luis Armendariz14
TTR -Unscheduled Down Time DMAICMean TTR Line 1 18 minCopyright 2010 Luis Armendariz15
Other Measurements DMAIC Time to Maintain TTM (Schedule Downtime) Cost to repair CTR Cost to maintain CTM Cost of Loss Cost of Yield LossCopyright 201016
Applying TPM: Analyze DMAICA :Define the resources, C&EBrainstorming and Fish BoneCopyright 201017
Applying TPM: Improve DMAIC I: Establish current and future flow map, describe all responsibilities ofoperators and technicians.Mean TBF Line 1 34 hrCopyright 201018
Applying TPM: Control DMAICC: TPM Improvement ProjectsProjectsEffectCIP cycle removedNoneSight glass changeLeakageTraining: ClampInstallationHumanErrorAdd cooling stepLeakageVisual Aid PostedStdWorkDue DateComp. DateCopyright 2010Note19
Applying TPM “Where to Start ?” Start with an equipment pilot1.Choose the right machine2.Choose the right person3.Choose the good timeCopyright 201020
TPM and other Lean Tools Overall Equipment Effectiveness Mistake Proof 5S Standard work Set up reduction Self maintenanceCopyright 201021
Justice to Root Cause Analysis “RCA”A systematic method that:Investigates as incident, attempts to understand the underlying causes andgenerates corrective actions to prevent and mitigate incidentsCommon Recommendations: Training Procedure Revision Repair or Replacement of broken equipment Restart the system Fix and go !Copyright 201022
Justice to Root Cause Analysis “RCA”Analysis TechniquesBrain StormingFishbone5 Why’sMethod of EliminationClue GenerationDiagnostic TreeFTALeveragingStratificationFMEACopyright 2010 Luis Armendariz23
So what was the root cause of the failure?FAILUREDesign &InstallationMaintenanceOperationsHuman ErrorMgt. ControlSystemCopyright 2010 Luis Armendariz24
Management Control System SystemOperationsWhat could go wrong?CHECKACTReactiveAnalysisRCAWhat went wrong?OEEHow much can you afford to lose?Copyright 201025
COST of Non TPM “ 30 Million Refinery Glitch Stalls Fuel Users – No Petrol for 2 Weeks” “Liquefied Natural Gas Project Back On Track after Production Train Repairs 300 Million Lost” “Refuelling Problems Delay 250 Million Terminal Operation – Jet Fuel PipesContaminated” “330 Hospital Patients Suffer Cold Winter Showers for Two Days – Risk of Spreading Infection”More than 4 million barrels of crude oil spewed into the seas off the U.S. Gulfcoast & 1.2 billion dollars in claimsCopyright 201026
TPM Implementation Challenges OEE measures RCA Leadership (Who Should Lead TPM ?) Employee training, development & compensation Employee Turn Over Collaboration Accountability Defined Responsibilities Spare parts and tools inventory mgt. 5S Visualize Standard Work and Maintenance Instructions Share best practicesCopyright 201027
TPM to infinity and beyond Asset Management and Spare Parts Inventory Management Predictive Maintenance Reliability Centered Maintenance, Ultra-Reliability and DFR Human Performance Information and Employee Communication Learning organization Management Control SystemCopyright 201028
Conclusion & Recommendation Decrease the firefighting ! Increase Collaboration between departments Avoids stress in a breakdown Visual Maintenance Standard Work Maintenance Increase productivityCopyright 201029
Questions ?Luis Armendarizluisarmen@prodigy.netResources:TPM - Japan Institute of Plant MaintenanceIIE –Process Industries webminars : http://www.iienet2.org/Landing.aspx?id 887Lean Management Database Tools: http://www.ProtimeSystems.comCopyright 201030
Total Productive Maintenance TPM Luis Armendariz, P.E. MBA, 6 . TPM identifies the 7 losses 1. Total time available – shutdowns/startup – scheduled main t. - calibration 2. Set-Up 3. Initial adjustment time OEE Availability x Performance x Quality Q P
TEKNIK PEMESINAN GERINDA 1 Program Studi: Teknik Pemesinan Kode: TM.TPM-TPG 1 (Kelas XII-Semester 5) . Teknik Pemesinan Frais (TM.TPM-TPF) Teknik Pemesinan Bubut (TM.TPM-TPB) TM.TPM- TPB1 (XI-3) (XII-5) TM.TPM- TPB 2 (XI-4) TM.TPM- TPB 3 TM.TPM- TPB 4 (XII-6) TM.TPM-TPF 1 (XI-3) TM.TPM-TPF 2 (XI-4) TM.TPM-TPF 3 (XII-5) TM.TPM-TPF 4 (XII-6) TM.TPM-TPG 1 (XII-5) TM-MK/EM 1 (X-1) TM.TPM-TPC)1 .
7 Chapter 1: Introduction B. Types of TPMs for TPM 2.0 The TPM-9665 series uses TCG 2.0 (Trusted Computing Group). The following SKUs are available: AOM-TPM-9665V, a vertical TPM without provisioning AOM-TPM-9665H, a horizontal TPM without provisioning AOM-TPM-9665V-S, a vertical server-sid
What is Total Productive Maintenance (TPM)? It can be considered as the medical science of machines. Total Productive Maintenance (TPM) is a maintenance program, which involves a newly defined concept for maintaining plants and equipment. The goal of the TPM program is to markedly increase production while, at the same time, increasing employee
2.2. Total Productive Maintenance (TPM) TPM involves all workers through small group activities [23]. TPM is a comprehensive maintenance system that includes preventive maintenance to prevent loss and waste [19]. In implementing TPM, 8 pillars are needed, namely, eight autonomous maintenance focused improvement, planned maintenance,
What is Total Productive Maintenance ( TPM ) ? It can be considered as the medical science of machines. Total Productive Maintenance (TPM) is a maintenance program which involves a newly defined concept for maintaining plants and equipment. The goal of the TPM program is to markedly increase production while, at the same
B. responsibility of each department. Therefore, the TPM is an Total Productive Maintenance (TPM) operational philosophy. All departments have an impact on DefinisiTPM According to the Japanese Institute of Plant Engineers (jipe) in Sharma et al. (2006, hal.262) TPM is defined a team-based maintenance strategies to maximize the
in the Total Productive Maintenance (TPM) philosophy [11]. In all this, higher level of production effectiveness is attained in terms of cost effectiveness, safety, employee motivation, product quality, reduced defects rate and market positioning in order fulfillment [10]. III. TOTAL PRODUCTIVE MAINTENANCE (TPM) REVIEW
4 BAB II LANDASAN TEORI . 2.1 Total Productive Maintenance (TPM) Total Productive Maintenance (TPM) merupakan suatu aktivitas perawatan yang mengikut. sertakan semua elemen dari perusahaan, yang bertujuan untuk . menciptakan suasana kritis (critical mass) dalam lingkungan industri guna mencapai zero defect dan zero accident (Kurniawan, 2013).