TRAINING
ON
TPM
EM
Y PL
AN O
MP YE
E
CO
UST
OM
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RPS SU
PP
LIE
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RAPL PRODUCTION SYSTEM
Employee Involvement Quality First
Safety Zero defect
Flexibility Jidoka
Respect for standard Problem solving
Continuous improvement Change point control
Kaizen Poka yoke
Process lead to result Abnormality control
Don’t judge & Don’t blame Person –Machine separation
Kaizen
Team Work 5S Standards Muda TPM
Elimination
Improvement begins with “ I”
Where does TPM fit in the house?
TPM is foundational
because Just in Time and
Quality cannot be
achieved without a robust
process.
Employees drive TPM to a
higher level.
2 22 Aug 2020 TPM
Content
What is TPM?
Purpose of TPM
Requirements for TPM
Where is TPM applicable
Explanation of TPM House
Strategy for TPM
Benefits
TPM in JPS Assessment
Links to documents and videos
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What is TPM?
TPM = Total Productive Maintenance
What would it be like to have no downtime?
1. Overtime would be minimal
2. More time to make proactive improvements
3. Production lead-time would be very predictable
4. Employee morale improved
Well executed TPM is a step towards True North
Zero Safety Incidents
Zero Defects
TPM target is to improve company results
Zero Breakdowns and to create a motivating working
environment based on waste elimination
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Purpose of TPM
To build up a profitable culture by:
Maintaining equipment and maximizing efficiency
with minimal cost.
Downtime
Quality Efficiency
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Starting Requirements for TPM
TPM Requires:
A good 5S Level
A working Suggestion System
Top Management commitment and energy
Training Material to support implementation
A proper training plan
A solid implementation plan
Management Follow-up
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Is TPM Applicable for only Production?
TPM is applicable in all areas of JRG
including:
− Logistics / Production control – Ensuring all
transport vehicles and other equipment are
operational when needed
− Office areas – Performing simple TPM tasks to
make sure Printer and other office equipment is
always ready to use.
− Engineering - Applying TPM principles with test or
tear down equipment.
− Facilities – Performing necessary PM's on
Compressors, Air handlers, etc.
− Test bay - All test equipment is ready to be used and
performs as needed.
− Etc.
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What is included in TPM?
Inspection & Cleaning Stds.
Breakdown Analysis
Significant Events
Lessons Learned
TPM is anything
that improves
Operator maintenance
Preventative machine Reliability,
Maintenance (PMs)
Quality, and Safety
Product Design
Machine History
Machine Design
5S
Management Follow-up
Leading2Lean
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Evolution of TPM
Repair machine when
breakdown happens
Replace parts before
breakdown
PM improvements to
Reactive Maintenance drive productivity
Operator driven
Preventive Maintenance repair
Productive Maintenance TPM drives
improvement
Total Productive Maintenance for production
everywhere (SQDCM)
Total Productive Maintenance the
for corporation
Where is your site or area?
9 22 Aug 2020 TPM
Key Players in TPM
Players needed to succeed include
− AMO
− Team Members
− Maintenance
− JPS Core team
− TPM Coordinator
− Safety
− Production Control
− Etc.
Remember a successful TPM Program
depends on a high level of teamwork!
10 22 Aug 2020 TPM
What is the Strategy for TPM?
Improving the People:
Operators do Autonomous Maintenance
Maintenance Staff does specialized maintenance
Production engineers design maintenance free equipment
Improving the Equipment: Improving the Company:
Raise efficiency by improving the current Create an empowered workplace
equipment
Performance improvement
Design equipment for immediate startup
To be profitable
Design equipment for minimum life-cycle cost
Do we need TPM?
Yes, We need TPM to simplify trouble shooting.
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Do we need TPM?
Yes, We need TPM to tell normal vs. abnormal.
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Do we need TPM?
Yes, We need TPM to create a good 5S
condition.
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Do we need TPM?
Yes, We need TPM to
reduce/eliminate
downtime. How long
will the machine be
down when the plug
falls out?
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Do we need TPM?
Yes, We need TPM to reduce the risk of defects (Quality).
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Do we need TPM?
Oil
Yes, We need TPM to reduce/eliminate the risk of Injury (Safety).
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TPM Understanding
Use
information to
Prevent
Cell Improves Problems &
Collect
Improve (TPM)
Information
Continue With TPM
to Run
Without
TPM
Cell Problems
(breakdowns) Fix
A
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TPM House
The TPM house focuses on
building a solid foundation through Total Productive
Maintenance
operator training and management
commitment:
− TPM Basics
− Safety (Lock-out / Tag-out (LOTO), power Autonomous Equipment
sources, & hazards) Maintenance Reliability
− L2L Utilization (People) (Process)
− Manufacturing Process Overview
− Product Function Overview
Management Commitment + Training &
Education
TPM
TPM House
Total Productive
Developing people to increase the Maintenance
ownership and pride:
− Operator Preventative Maintenance
(OPM’s)
− Maintenance and operators Autonomous Equipment
partnering together Maintenance Reliability
− Preventative Maintenance (People) (Process)
Improvements (PMI’s)
− Applying lessons from daily
experience
− Focusing on better downtime Management Commitment + Training &
information Education
TPM
TPM House
Increasing the robustness of our
equipment to achieve:
Total Productive
Maintenance free equipment Maintenance
Zero breakdowns
Autonomous Equipment
Increase capacity and lower cost Maintenance Reliability
(People) (Process)
Measure and monitor the performance
of the line/ equipment
Continuous approach to improving the Management Commitment + Training &
reliability of the line/ equipment Education
Stable reliable process leads to
improved quality and reduces
complexity of problem solving
TPM
For Example
Minutes of Downtime
42 % Reduction
in Downtime
TPM is not just cleaning, it is preventing downtime.
It’s about gaining the knowledge to know what to do at the
right time.
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Benefits:
Reduces lead-time & inventory
Increases teamwork & employee morale
Increases ownership
Improves skills & ability
Improves quality & safety
Creates continuous flow
Reduces downtime
Decreases spares and repair cost
Reduces scrap
Increases proactive work
Can we afford not to embrace TPM???
23 TPM
The Items in JPS Assessment for TPM
In RPS Assessment for TPM, we have the
following items to evaluate the level and
status of teamwork
− TPM Vision (Manufacturing Floor, Testing,
Logistics & Facilities)
− Autonomous Maintenance – Ownership
(Manufacturing Floor, Testing, Logistics &
Facilities)
− Process Reliability – Equipment Robustness
(Manufacturing Floor, Testing, Logistics &
Facilities)
− Standards / Documentation (Manufacturing
Floor, Testing, Logistics & Facilities)
24 22 Aug 2020 TPM
“RPS is a Journey, not a Destination”
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