TPM

Total Productive Maintenance (TPM)

TPM – A Definition

Total Productive Maintenance (TPM) is

a manufacturing initiative for

optimizing the effectiveness of

equipment.

Why Do We Need TPM?

• Cannot become Lean if we have defective or interrupted supplies

• Cannot have zero defects if the equipment does not function properly

• Cannot avoid supply interruptions, if we have equipment breakdowns

• Zero accidents and cleanliness are not possible if all systems of the equipment do not function properly

TPM Goal of Zero Losses

• Zero breakdowns• Zero defects • Zero losses due to wasted time• Zero accidents• Zero leaks

Common Reasons for Losses

• Lack of spare parts• Lack of maintenance scheduling• Lack of equipment availability• Lack of planning• Untrained craftsmen, operators, and management• Poor housekeeping• Equipment does not match the needs• Poor communication• No preventative maintenance programs• No sustained commitment (involvement)

Role of the Operators in TPM

• Perform routine services, such as cleaning, lubricating, and inspections.

• Keep equipment in good operating condition by following standard practices, visual inspections, etc.

• Detect deterioration or abnormalities, including wear, quality problems, etc., and get them fixed

• Continue to acquire additional operational and maintenance skills

• Adjustments, Set-Up Reduction, etc.

Total Productive Maintenance

Preventive Proactive

Predictive

•Introduction to OEE

What is OEE?

• OEE stands for Overall Equipment Effectiveness

• OEE is a measurement that represents the percentage of time a machine was actually producing quality parts compared to the time it was planned to be

• OEE provides a measure of equipment’s actual productivity compared to the ideal productivity, during a specified period

of time

• The difference between actual and ideal is waste, which must be eliminated

Availability Goal

%

Quality Goal

%

Performance Goal

%

OEE Goal

%

Missing Information

Six Big Losses

• Six Loss Categories• Idle Time Losses

• Set-up Time Losses

• Maintenance Time Losses

• Miscellaneous Time Losses (All Others)

• Quality Time Losses

• Slow-down (Speed) Losses

Objectives of OEE Measurement

•Monitor critical equipment performance•Monitor TPM implementation•Better evaluate capital needs•Analyze the loss data to •Capture operator’s notes and actions. •Monitor autonomous maintenance•Monitor impact of set-up reduction efforts

What is Autonomous Maintenance?

• Similar words and phrases for autonomous • Self-governing• Independent• Self-ruling• Free• Non-centralized

• A self-governing (by the operators) equipment maintenance program

Seven Steps of Autonomous Maintenance

1. Perform initial cleaning & inspection2. Eliminate causes of contamination & inaccessible areas3. Develop cleaning, lubricating, and inspection standards4. Provide basic training in machine’s function and controls to enable

effective general inspection5. Enhance and implement autonomous inspection standards &

schedules6. Implement workplace organization & housekeeping, employing 5S &

visual controls7. Follow up on all the above steps and advanced improvement activities




effective general inspection5. Enhance and implement autonomous inspection standards & schedules6. Implement workplace organization & housekeeping, employing 5S &


Cleaning

• Ensure that the machine is kept clean inside and out

• Develop low cost methods for preventing lubricant contamination

• Avoid using compressed air for cleaning

• Devise innovative methods for flushing chips and swarf and to prevent them from entering between sliding surfaces

Inspections

• Check belts, chains, couplings, conveyors• Check for loose or missing nuts, washers, bolts• Check for excessive vibration• Check for excessive noise • Check for excessive heat• Check for leaks• Check for dirty filters• Check for fluid levels• Check gages for pressures

Lubrication

• Ensure that all lubrication reservoirs are filled to the proper full mark• Check for excessive heating of lubrication• Insure lubricants are changed out in a timely manner• Implement oil sampling program• Ensure that all grease fittings are functional and are being greased as

per the schedule

Abnormalities to look for

• Missing, broken or damaged parts• Wear of sliding surfaces• Play, looseness, sagging, excessive movements• Warped, deformed, misaligned• Rust & other surface damage• Leaks, splattering• Vibration, shaking• Unusual sounds, abnormal heating• Unusual smell & discoloration

Broom not stored

Grit & Grime

480 Volt Electrical cover blocked open

Cover on motor wiring box missing

Missing Mounting Bolt - AbnormalityConduit pulled out of Connector

No Oil in lubricator

Abnormality – Heavily contaminated air filter element

Contaminated Hydraulic Motor Fan - Abnormality

Cover loose - abnormality

Machine parts lying around on machine

Gage broken and full of water

Set Up parts laying on machine

1. Perform initial cleaning & inspection2. Eliminate causes of contamination & inaccessible areas3. Develop cleaning, lubricating, and inspection standards4. Provide basic training in machine’s function and controls, to enable




Eliminating Contamination

• What contaminates? • Leaking or splattered fluids – oil, water, coolant • Chips or swarf• Foreign matter – dust, packing material, mist

• Examples of improvements• Repair leaks, reduce overflows• Install shields / covers to contain cutting debris• Install dirt and debris collectors• Devise efficient washing methods• Reduce/control air flow

Some of the Causes of Inaccessibility

• Hidden locations• Behind the machine, behind covers• Obscured by other parts, hoses, pipes, cables• Moving parts have to be aligned in certain way

• Difficult locations• Go through hazardous chips• Go through oily areas• Possibility of exposure to electric shock, high pressures, high

temperature• High up from the floor or too close to the floor





Lubrication Standards Must Specify

• Lubrication points• Criteria for acceptance

• Oil level within range• Film of oil on surface• Sufficient grease

• Type of lubricant to use• Tools needed to apply lubricants

• Barrel pump• Grease gun

• Frequency for checking & lubrication• Responsible person for checking

Studer S20 CNC Universal Cylindrical Grinder

Sr. No. Location Method Criteria Shift Day Week 2-Week MT Min Who1 Control Panel Wipe with soft rag Dry & free of grime X2 Front of machine Spray cleaner & rag Dry & free of grime X3 Door window Spray cleaner & rag Dry & free of grime X4 Base of machine Spray cleaner & rag Dry & free of grime X5 Top of machine Spray cleaner & rag Dry & free of grime X6 Outside of control

cabinetSpray cleaner & rag Dry & free of grime X

7 Back of machine Spray cleaner & rag Dry & free of grime X8 Floor area Sweep & mop Clean & dry X9 Inside of machine Wash down the

inside with coolant hose. Apply WD-40 lubricant to all bare metal surfaces

Clean & free of swarf

DB

4/1/2013DateStuder S20CNC Universal Cylindrical GrinderMachine

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Example – Provisional Cleaning Standard

Sr. No. Location Method Criteria Shift Day Week 2-Wk Month other Who1 Air pressure gage Visual Check pressure - set 5 bar X DB

2 Water separator Visual No water build up in bowl X DB3 Oil regulator filter Remove filter &

elementClean or replace element, clean glass bulb

X DB

4 Oil regulator Visually check oil level

Fill as necessary with DTE 24 oil

X DB

5 Oil regulator dropper

Visually count drops

Must be 5-10 drops per minute. Adjust as needed. Output flow should be fine mist

X DB

6 Pneumatic cabinet

Visually check cabinet

No crimped / broken lines X DB

Machine

A. Main Air Solenoid ValveB. Pressure Reducer ValveC. Water SeparatorD. Solenoid For Dry AirE. LubricatorF. Controlled Dry Air For Spindle Nut Lubrication and Internal GrindingG. Non-Controlled Dry Air For Dry Barrier Air & Internal GrindH. Oil Saturated Air for Air Cushion, Pneumatics, and Calmping Devices

4/2/2013DateStuder S20CNC Universal Cylindrical Grinder - Pneumatics

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Example –Provisional Lubrication & Inspection Standard

Operator Checklist K/T 180 GD-15 - GD-16Operator Week ending

Daily Mon Tue Wed Thu Fri Sat Sun

1. Clean both tool changers2. Clean all the way covers3. Clean all pallet stands4. Check hyd. Tank fluid level

Weekly1. Clean the Hyd. Tank & motor2. Clean both Z-axis3. Inspect machine for abnormalities

Monthly1. Check hydraulic filters

TPM Operator Check List

Machine: K&T Rotor Slot Mill Date: May 1999

# Location Method Criteria Shft MON TUE WEDTHU FRI SATSUN1 Complete

head and column areas

Spray bottle, wipe with rag

Free of grime, dry to touch X

123 [][][]

123 [][][]

123 [][][]

123 [][][]

123 [][][]

123 [][][]

123 [][][]

2 Electrical cabinet


Free of grime, dry to touch X

123 [][][]

123 [][][]

123 [][][]

123 [][][]

123 [][][]

123 [][][]

123 [][][]

TPM PROVISIONAL CLEANING STANDARD

1

2

Machine: K&T Rotor Slot Mill Date: May 1999

# Location Method Criteria Shft MON TUE WED THU FRI SAT SUN3 Front spindle

areaSpray bottle, wipe with rag

Free of grime, dry to touch

X123 [][][]

123 [][][]

123 [][][]

123 [][][]

123 [][][]

123 [][][]

123 [][][]

4 Overarms and arbor support


Free of grime, dry to touch

X123 [][][]

123 [][][]

123 [][][]

123 [][][]

123 [][][]

123 [][][]

123 [][][]

5 Haas indexing fixture


Free of grime, Spray with WD-40

X123 [][][]

123 [][][]

123 [][][]

123 [][][]

123 [][][]

123 [][][]

123 [][][]

TPM PROVISIONAL CLEANING STANDARD

3 4

5

Summary Steps One, Two and Three

Step 1 – Stabilize equipment condition

Step 2 – Stop accelerated deterioration

Step 3 – Maintaining basic equipment condition

Steps One, Two and Three

together constitute the beginning

phase of a TPM program for zero failures

Safety Rules for Team Members

• It is the responsibility of each team member to use safe practices at all times to avoid injury to themselves and to fellow employees

• Verify that equipment has been properly locked out, tagged out before starting work

• Verify that all stored energy has been released• Ensure that the air pressure is relieved from all air lines and

components• Ensure that the hydraulic pressure from all lines & components is

relieved• Electronic technicians should ensure that all capacitors and circuits

are dischargedcontinued…

Safety Rules for Team Members

…continuation

• Appropriate safety glasses with side shields must be worn at all time

• Safety shoes must be used to prevent foot and toe injuries• Lift the correct way and safe way

• Bend your knees and keep your back straight• Use of hand tools

• Use the correct tool for the job• Make sure the tools are in good condition• Use the tools in the correct manner

continued…

Cleaning and Inspection Activities

• Perform visual inspection noting all abnormalities• Clean by removing dirt and grime• Use all five senses to discover additional abnormalities• Record all abnormalities• Take pictures of abnormalities• Identify and record areas for improvements• Gather data for provisional standards





Guidelines for Training to Sustain Step 4 Objectives

• Training topics are selected based on the site’s needs• TPM teams develop the training material• Training is provided one topic at a time• Implementation is reinforced through practice• Training material is regularly updated• Training should be repeated for reinforcement

Training Considerations

• Who provides training?• Maintenance person• Team leader• Member of management• In-house training department• Other – consultants, schools, community colleges,

on-line, correspondence• Self learning – books, CD’s, videos

Training Topics

• Lubrication• Fasteners (Screws, Nuts, Bolts & Washers)• Pneumatics• Hydraulics• Electrical Systems• Drive Systems


1. Perform initial cleaning & inspection2. Eliminate causes of contamination & inaccessible areas3. Develop cleaning, lubricating, and inspection standards4. Provide basic training in machine’s function and controls to

enable effective general inspection5. Enhance and implement autonomous inspection standards

& schedules6. Implement workplace organization & housekeeping,

employing 5S & visual controls7. Follow up on all the above steps and advanced improvement

activities

Step 5 Activities

• Review all tasks with maintenance to resolve any inconsistencies between the maintenance department and operators

• Ensure that all equipment improvement activities have been incorporated into the standards

• Ensure that up-to-date standards are placed in all the autonomous maintenance manual

Autonomous Maintenance – Audits

Objective of the audit should be• Ensure that all activities are being carried out• Verify that TPM teams are identifying and pursuing root causes of

breakdowns• Verify that visual controls are implemented• Verify operator proficiency in carrying out tasks• Ensure that the methodology is being followed correctly



effective general inspection5. Enhance and implement autonomous inspection standards &

schedules6. Implement workplace organization & housekeeping, employing 5S

& visual controls7. Follow up on all the above steps and advanced improvement

activities

Visual Controls

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Oil Drums

Oil Supply Cans With Spigots

Lubrication Tools

Identified Lubrication Points

Example – Visual Control For Machine Lubrication

Date Developed: March 2005

Lubrication Visual Controls

Dept / Machine: All

Developed By: ATS Team

1

2 3

Red Red Grease Shell Retina LIZ 2Substitute Aeroshell 22

Green Shell 46 Hydraulic Oil

Blue Texaco Regal R & O 220

Yellow Shell 32 Lubricator

Visual Controls Developed for all Lubrication Types

Color of Lubrication Tool Matches Visual Control

Visual Controls Marked at Lubrication Points on Machine to Ensure Proper Lubrication

Lean One Minute Lesson

Daily

Mobil

#32

Oil Type

Hi – Low Level Marks

Oil Inlet

Hydraulic Tank

H

L

Paint Lube Type

Color Dot

Mark Hi-Low Points

Example – Visual Control For Machine Lubrication

Gages With Alarms

Gages Oriented to Point UP

22# 35# 10#

Labeled Gages

Gages With Marked Limits

Gages In One Place

Visual Control Examples – Gages

Materials/ Process/ Object Contents/quantity in storage and transport units Quantity in production unit (lot size) Date of process completion, product delivery Production sequence - where last - where next Process priority FIFO Method, frequency and results of inspection Designation of long - waiting material Deadline and individual assigned to dispose of defective or long waiting material

Storage Space Quantity of work in process Maximum allowable in storage Separate space for conforming and non-conforming material Establish methods for placement and stacking Means of regulating use (FIFO)

Equipment/ Safety Schedule stop or breakdowns Workload of major equipment for next period Routine equipment maintenance procedure Maintenance routing for tools, fixtures, measuring instruments Routine measure for minor repairs parts and adjustments Location of frequently used tools

Quality/ Productivity Daily defect reports Daily production output Scrap results Actual results compared to monthly schedule

Areas of Visual Control Opportunities

Gauge marking film . . .



Zebra cards cut to fit make the fluid levels show up!

“Plastic-protected” tag for harsh conditions

Fluorescent orange and green cardstock tags

¡PROBLEM TAG

Date___________ Shift _______ (part 1)

(NNNNN)By________________________Problem: 4 o Operation o Electrical o Instrument/Control o Mechanical o Utility/Facility o Lubrication o Other__________Brief Description of Problem:

PROBLEM TAGDate___________ Shift _______ (part 2)

(NNNNN)By________________________

Location/System/Equipment/Part I.D.:

Problem: 4 o Operation o Electrical o Instrument/Control o Mechanical o Utility/Facility o Lubrication o Other__________Description of Problem: (continue on back)

Possible Impact of Problem: 4 o Availability (Uptime) o Waste o Performance/Speed o Cost o Quality of Product o ________ o Environmental o Safety

Corrective Action Plan:W/O # __________

By:___________________Date:__________By:___________________Date:__________By:___________________Date:__________

Root Cause/Action: (continue on back ð )

Date Completed: _________ OK _________© 1996 Strategic Work Systems, Inc.—Mill Spring, NC 28756

<<My Documents\Visual Systems Book\Problem Tag.eps>>

Inspect equipment and tag problems… 11

22

• Pin-points the actual location

• Acts as a reminder

• Use as a mini-work request

• Communicates to others: Part 1 on the equipment – Part 2 in the area

Many uses for industrial strength paint pens . . .


Match marking critical nuts and bolts after proper tightening . . .


Match marking critical nuts and bolts after proper tightening . . .

Temperature labels monitor 24 hours, 7 days, all year

Vibration analysis pickup discs

Paint pens mark acceptable ranges in green on temperature labels

Seal critical nuts and bolts to show signs of tampering or loosening.

Rotating targets for motors, fans and pumps in storageprevents “false brinelling” of bearings

Glue or tape to ends of shaft and rotate at specified intervals

with color of the month at 12:00 o’clock position





Objectives of Step 7

• Strengthen & consolidate TPM teams throughout the plant

• Continue to standardize improvement activities

• Implement results to all other equipment / areas

• Make progress per the master plan

• Continues to build operator’s diagnostic and maintenance skills