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The Lean Enterprise Introduction to TPM – Total Productive Maintenance Learning Objectives Learn the basic philosophy of TPM Explain OEE and how it contributes to a TPM project, explore OEE components; define and calculate OEE List 6 major components of equipment loss Review and adopt the 7 steps to Autonomous Maintenance TPM – The Need Process Industry relies heavily on equipment that is integrated and runs continuously When down, losses are costly With lower inventories, machines need to be reliable Machining and Assembly industries becoming more mechanized to save manpower and do difficult jobs More machines to maintain Need to save energy TPM – The Philosophy TPM aims at using equipment to its maximum and aids in reducing Life Cycle Costs (LCC) In other words - going all out to eliminate the Losses (Waste) caused by the equipment TPM improves work activities that deal with Equipment Set-up, Operating parameters, Maintenance, Tear down, Repairs and Breakdowns It specifically aims at the complete elimination of the ‘six major losses’ while striving for a goal of zero unscheduled downtime TPM - The Six Major Losses (Waste) Downtime Losses (1) Equipment failures (2) Set-up and adjustments Speed Losses (3) Idling and minor stoppages (4) Reduced speed (actual operating vs. designed) Defect Losses (5) Defects in process (6) Reduced yield between start of production and stable production OEE Formulas TPM attacks 6 major “Losses” plus Elimination of other Wastes (Mura, Muri, Muda) Operator Time Losses Manpower losses due to operation time being done more slowly than standard time (Cycle Time Standard Time) Material Losses Losses in yield due to ‘inherent waste’ (cut-off stock, set-up pieces, prototype, etc) Energy losses such as electricity, gas, and water when machinery is not doing value-added work Idling losses due to inadequate sensors and product buildup on conveyors and chutes Best PracticesWorld-Class Goals (A TPM “V