IntroductionUnit 4, IDA Industrial Estate,
Purcellsinch,
Kilkenny,
Ireland.
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This document has been formulated in order to explain to organizations about TPM, the requirements of the 5S & Visual Workplace in simple terms and some of the benefits of the if they are applied correctly.
We hope you find this document useful and please do not hesitate to contact us with any questions.
TPM Defined
TPM is a company-wide approach for improving the effectiveness, longevity, and uptime of mechanical equipment. It is key to Lean Business because it attacks major wastes in production operations in the form of downtime and quality losses.
TPM was developed originally to help a supplier meet the stringent requirements of the Toyota Production System. In today’s competitive world, TPM is considered a critical ingredient to World Class Manufacturing.
TPM harnesses the efforts of all employees focusing on quality, safety, and efficiency.
Value Stream
| Pillar | Activities |
|---|---|
| Focused equipment and process improvement | Measurement of equipment - or - process-related losses and specific improvement activities to reduce the losses. |
| Autonomous maintenance | Operator involvement in regular cleaning, inspection, lubrication, and learning about equipment to maintain basic conditions and spot early signs of trouble. |
| Planned maintenance | A combination of preventive, predictive, and proactive maintenance to avoid losses, and planned responses to fix breakdowns quickly. |
| Quality maintenance | Activities to manage product quality by maintaining optimal operating conditions. |
| Early equipment management | Methods shorten the lead time for getting new equipment online and making defect-free products |
| Safety | Safety training, integration of safety checks, visual controls, and mistake-proofing devices in daily work. |
| Equipment investment and maintenance prevention design | Purchase and design decisions informed by costs of operation and maintenance during the machine’s entire life cycle. |
| Training and skill building | A planned program for developing employee skills and knowledge to support TPM implementation. |
Common Problems
- Hydraulic/Pneumatic lines & fittings leak.
- Grease fittings are dry & not labeled.
- Oil reservoirs are not changed frequently enough.
- Pump motors are coated with dirt & oil film.
- Air/oil filters are not changed often & are very dirty.
- Electrical cabinet fans are coated with dirt/dust.
- Gauges are hardly used, dirty and not labeled.
- Electrical connections are loose & wires are damaged.
- Coolants are not at the proper concentration.
- Bolts & nuts are loose.
- Guards/shields don’t contain chips & cutting fluids.
TPM Objectives
Develop Equipment Knowledgeable People Who Will Exercise Their Full Potential
Create Well Engineered Equipment & Use it to Build in Safety & Quality
Maximize Overall Equipment Effectiveness
Create an Enthusiastic Work Environment
OEE
OVERALL EQUIPMENT EFFECTIVENESS
How effectively does your
equipment run?
When you
plan to run it?
OEE = Availability X Performance Efficiency X Rate of Quality
Six Major Losses
- Breakdowns
- Setup & Adjustment
- Idling & Minor Stoppages
- Startup
- Reduced Speed
- Quality Defects & Rework
OEE Example 1
OEE Example 2
OEE Example 3
Utilisation
Equipment Availability = 1440 minutes (24 hours)
Planned Downtime:
No 3rd shift = 420 Min.
Lunch (2 shifts) = 60 Min.
Dept. Meeting = 20 Min.
Total = 500 Min.
1440 Min. - 500 Min. = 940 Min. (Net Operating Time)
960 ÷ 1440 = 65.3% Equipment Utilization
This is where OEE Starts!
Availability
940 Min. (Net Operating Time)
- 150 Min. (Set-Ups)
790 Min. (Planned Uptime)
790 Min. (Operating Time)
- 140 Min. (Breakdowns/ Losses)
650 Min. (Running Time)
650 ÷ 790 = 69.14% Availability
Efficiency
650 Min. (Running Time)
- 225 Min. (Minor Stoppages)
425 Min.
425 ÷ 650 = 65.4% (Efficiency)
Jams
Chips
Inserts
Speed Losses
Rate of Quality
425 Min. (Usable Operating Time)
- 56 Min. (Time Used Manufacturing a Defective Part))
369 Min.
369 ÷ 425 = 86.8% (Rate of Quality)
Final Calculation
OVERALL EQUIPMENT EFFECTIVENESS (OEE) Calculation
OEE = Availability X Performance Efficiency X Rate of Quality
OEE = 69.1% x 65.4% X 86.8%
OEE = 39.2%
Total Operating Time
Preventative
Identify Potential failures in their infancy.
Monitor the equipment utilizing special predictive tools.
Regular service intervals.
Schedule work to replace or repair worn or defective parts.
MACHINE OPERATORS with proper training can detect 75% of all equipment related problems at an early stage.
Inspection
DAILYMark critical areas of equipment.
Check sequentially, beginning of each shift Pressure gages/ oil levels / contamination / leaks, etc.
Note deviations & notify Maintenance to determine if life-threatening.
Should not take more than 5 minutes, typically not over 2 minutes.
WEEKLYAll team members participate: - 5S, Filters, Up to 1 hour.
MONTHLYMostly by maintenance – Planned
ANNUALMajor PM’s - Planned
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ARC Management Systems is a trading name of SKARC Europe Ltd.