BTM 4713
LEAN MANUFACTURING SYSTEMS
TOPIC 3: TOTAL PRODUCTIVE
MAINTENANCE (TPM) 2
LECTURER:
DR. MUSFIRAH ABDUL HADI
Customer Satisfaction
The goal of TPM is to maintain equipment so it will be able
to achieve 100% on-demand availability for immediate use
by the next process or customer.
All can be done by reducing;
• Equipment breakdowns, unplanned downtime
• Scrap/rework
• Reduced productivity
• Equipment start-up losses
• Set-up time
TPM Goal
• Maximize Overall Equipment Effectiveness by
minimizing equipment-related losses.
• Provide a system of comprehensive maintenance for
the life cycle of equipment.
• Involve departments that plan, design, use, and
maintain the equipment.
5 TPM Principles
1. Improve Overall Equipment Effectiveness
(OEE)
2. Improve operators in daily maintenance
3. Improve maintenance efficiency and
effectiveness
4. Train all personnel
5. Establish early equipment management and
maintenance prevention programs
TPM Prerequisites
1. Must be measuring OEE
2. 5S workplace organization
Main Components of TPM
• Autonomous maintenance – operators take ownership
of equipment and conduct regular cleaning, lubricating
and minor maintenance themselves.
• Strengthened preventive maintenance system –
includes scheduled, predictive and condition-based
maintenance programs.
Type of Maintenances
1. Breakdown maintenance
• It means that people waits until equipment fails and repair
it. Such a thing could be used when the equipment failure
does not significantly affect the operation or production or
generate any significant loss other than repair cost
2. Preventive Maintenance
• Preventive Maintenance is periodic maintenance that
retains the condition of equipment and prevents failure
through the prevention of deterioration, periodic
inspection, and equipment condition diagnosis. PM
includes cleaning, inspection, lubrication and tightening.
Type of Maintenances
3. Periodic maintenance (Time based maintenance - TBM)
• Time based maintenance consists of periodically inspecting,
servicing and cleaning equipment and replacing parts to
prevent sudden failure and process problems.
4. Predictive maintenance
• Service life of important part is predicted based on
inspection or diagnosis, in order to use the parts to the limit
of their service life. Compared to periodic maintenance,
predictive maintenance is condition based maintenance. It
manages trend values, by measuring and analyzing data
about deterioration and employs a surveillance system,
designed to monitor conditions through an on-line system.
Type of Maintenances
5. Corrective Maintenance:
• Corrective Maintenance improves equipment and its
components so that preventive maintenance can be
performed reliably. Equipment with a design weakness is
redesigned with corrective maintenance to improve
reliability or maintainability.
6. Maintenance Prevention
• Maintenance Prevention deals with improving the design of
new equipment. Current machine data (information leading
to failure prevention, easier maintenance, prevention of
defects, safety, and ease of manufacturing) are studied and
designs are incorporated in new equipment.
Overall Equipment
Effectiveness (OEE)
• OEE is used to see how effectively a manufacturing operation is
utilized.
• OEE is the product of the three measurements below.
Equipment Availability
Measures how often equipment is not producing
Equipment Efficiency Performance
Measures actual machine cycle time
Equipment Quality Performance
Compares the # of good pieces produced/total number
produced
Elements of OEE
Inconsistent Timings, Insufficient Skills. Poor Planning & Scheduling, Different
Set-up
methods, Poor Tooling, Poor start up controls, Missing Parts, Insufficient support,
Excessive start-up adjustment
Availability
losses Lack of Maintenance, Low Operator Interest, Not knowing of problems, Poor
Breakdown Training, Design Problems, Inferior Material
Minor Material not Available, Change over at start/end, Jams/misfeeds/ overloads,
Stoppages Operator Error, Operator Absence
Overall Performance
Equipment losses Unclear Design Specs., Poor Maintenance History, Incorrect Settings, Poor
Effectiveness Speed
Training, Speed Deliberately Reduced, Inconsistent Material
losses
Start-up Poor Product Changeover, Inconsistent Materials, No start-up check lists, Waiting
losses for Temp. Pressures, Minor adjustments
Quality
losses
In process Environmental Conditions, inconsistent Materials, Process not followed, Poor
losses Calibration, Gauges not calibrated properly etc.
10
Equipment Availability (EA)
EA = Scheduled Production Time - Unplanned Downtime
Scheduled Production Time
Since, Uptime = Scheduled Production Time – Unplanned Downtime
Then, EA = Uptime___________
Scheduled Production Time
Equipment Efficiency
Performance (EEP)
EEP = Actual Output
Target Output
Equipment Quality
Performance (EQP)
EQP = Total no. Produced – Total no. Defective
Total no. Produced
Since, No. of good pieces = Total no. Produced – Total no. Defective
Then, EQP = No. of Good Pieces
Total no. Produced
Overall Equipment
Effectiveness (OEE)
OEE = (EA) X (EEP) X (EQP)
Current World Class benchmarks for these are:
EA = 90%, EEP = 95%, EQP = 99%
OEE = 85%
Overall Equipment
Effectiveness Calculation
Available time - Downtime
Equipment Availability=
Availability
OEE (in %) =
420 min - 80 min
420 min factor 81%
Equipment Performance=
Running time - Performance loss X
Running time
340 min – 70 min
=
340 min factor 79.4%
Quality =
Productive time - Quality loss time X
= Productive time
270 min - 20 min
270 min factor 92.6%
Overall Equipment Effectiveness = 59.6%
15
OEE Exercise
Excersice:
Item Data
Shift length 8 hrs = 480 min.
Short Breaks 2@ 15 min. = 30 min
Meal Break 1 @ 30 min = 30 min
Down Time 47 min
Ideal Run Time 60 pieces per min
Total Pieces 19,271 pieces
Reject Pieces 423 pieces
Total Output = 18,848 pieces
Answer
a) Availability
Total loss time = 480 – (30 + 30 + 47) min
= 373 min
The calculation of the availability rate is:
Availability = 373 / 480 x 100
= 77.7%
Answer (Cont…)
b) Efficiency Performance
Theoretical Output = 373 x 60
= 22,380 parts
The calculation of the performance rate is:
Performance = 19,271 / 22,380 x 100
= 86.1%
Answer (Cont…)
c) Quality
Good parts = 19,271 – 423
= 18,848 parts
The calculation of the quality rate is:
Quality = 18,848 / 19,271 x 100
= 97.8%
Answer (Cont…)
d) OEE
OEE = Availability X Efficiency Performance X Quality
The calculation of the OEE is:
OEE = 0.777 x 0.861 x 0.978
= 0.654
Therefore,
OEE = 65.4%
OEE Exercise
Calculate the OEE.
Answer: 30.24%
How to Improve OEE ?
Data collection is the most important action to increase OEE
Collect data for all downtimes Data analysis and Make improvements
and losses on the machine visible measure visible and implement
35
Analysis
Repairs 30 Autonomous Mainten.
25
20
Change over, Adjustm. 15
10
Preventive Maintenance
5
Tool change Changeover reduction
Repair ChangeoverTool change Scrap Minor Stopp.
Minor stoppages 33 26 16 7 3
Standardize tooling
Scrap, rework OEE Trend Improved machine
Target 2018 reliability
Standardisation
J F M A M J J A S O N D
22
Summary
• TPM can significantly improve a plant’s quality, productivity, and product
delivery
• TPM can generate culture changes in a plant.
• The only long term competitive advantage any company can have is its
people.
• TPM implementation depends on condition of equipment, work culture,
equipment management, and maintenance effectiveness.
• TPM Benefits
Reduced equipment downtime
Increased equipment productivity
Increased plant capacity
Lower maintenance and production costs
Approaching zero equipment caused defects
Enhanced job satisfaction
Increased Return-on-investment
