LECTURE 6
TOTAL
PRODUCTIVE
MAINTENANCE
(TPM)
What is TPM?
TPM is a companywide approach for improving the effectiveness and
longevity(length of service) of machines
It is a key to lean manufacturing because it attacks major waste in production
operations
OEE or Overall Equipment Effectiveness is a key measurement by TPM
What is OEE?
Many people are familiar with the idea of “efficiency”
Usually reflects the quantity of parts a machine or
a person can produce in certain time
OEE are different in several ways
1. Quantity Over Time is Only Part of OEE
OEE includes not only performance but also other two factors , availability and
quality.
OEE = performance X avaliability X quality X 100%
Performance : comparison of the actual output with what the machine should
be producing(actual capacity)
Availability : a comparison of the potential operating time and the time is in
which the machine is actually making products
Quality : a comparison of the number of products made and the number of
products that meets the customer’s specification
Measuring Effectiveness of Equipment
The effectiveness of facilities
• is its best possible return generated
• is calculated as percentage of each group of 6 big
losses
Overall Equipment effectiveness (OEE) =
%Availability x %Performance x %Quality
• Breakdown losses • Idling and minor • Scrap and
stoppage losses rework losses
• Set-up and
adjustment losses • Speed losses • Start-up losses
a comparison of the potential Performance : comparison a comparison of the number
operating time and the time of the actual output with of products made and the
is in which the machine is what the machine should number of products that
actually making products be producing(actual meets the customer’s
capacity) specification
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OVERALL EQUIPMENT EFFECTIVENESS
(OEE)
Is a “best Practices” metric that identifies the percentage of planned production
time that is truly productive.
• 100% - Perfect
• 85% - World Class Manufacturing
• 60% - Typical
• 40% - Low
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TPM Objectives
• To maximize overall equipment effectiveness (Zero
breakdowns and failures, Zero accident, and Zero
defects etc) through total employee involvement
• To improve equipment reliability and maintainability as
contributors to quality and to raise productivity
• To aim for maximum economy in equipment for its
entire life
• To cultivate equipment-related expertise and skills
among operators
• To create a safe working environment(Zero Accident)
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Five fundamental TPM activities
1. Autonomous maintenance
Operator involvement in regular cleaning, inspection, lubrication and learning about equipment to
maintain basic conditions and spot early signs of trouble
2. Equipment improvement
Measurement of equipment or process related losses and specific improvement activities to reduce
the losses
3. Quality maintenance
Activities to manage product quality by maintaining optimal operating conditions
4. MP(Maintenance Prevention) system
A combination of preventive, predictive and proactive maintenance to avoid losses and planned
responses to fix breakdown quickly
5. Education and training
A planned programmed for developing employee skills and knowledge to support TPM
implementation
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SIX BIG LOSSES
% Availability
% Performance
% Quality
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Availability : a comparison of the potential operating
time and the time is in which the machine is actually
making products
Performance : comparison of the actual output with
what the machine should be producing(actual
capacity)
Quality : a comparison of the number of products
made and the number of products that meets the
customer’s specification 11
Loading Time – Breakdown & Setup loss
%Availability = -----------------------------------------------x 100
Loading Time
Where Loading Time
= Planned Production =Operation Time – Break Time – Planned
Maintenance time
Quantity Produced
% Performance = ----------------------------------- x 100
Time run x Capacity/Given time
Target output
or
Time run – Minor stoppages – Reduced speed
= -------------------------------------------------------------- x 100
Time run
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% Quality =
Amount produced –Amount defects –Amount re-processed
---------------------------------------------------------------------x 100
Amount produced
or Time run – Defect time – Re-processing time
= -------------------------------------------------------------- x 100
Time run
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Example 1
A medium volume manufacturing facility with a capacity of
producing 2 parts/minute actually produced 800 parts in a
planned running 2 shifts of 8 hours each. It had breaks and
scheduled maintenance for 40 minutes and also faced 40
minutes breakdowns and 1 hour 20 minutes for changeover and
adjustment. Number of rejects and re-works were 10 and 6 parts
respectively. Calculate its overall effectiveness
Planned production time = 2x8 hrs. = 960 minutes
Loading time = 960-40 (breaks & scheduled maintenance) = 920 min.
Down-time =40 (Breakdowns) + 80(Changeover & adjustment)= 120
Loading time – Down time 920 - 120
%Availability = ----------------------------------------X100 = ----------------x100 = 87%
Loading time 920
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Example 1 (Contd.)
Quantity produced 800
%Performance = --------------------------------x100 = ----------------------- x100 = 50%
(Loading Time – Downtime) x Capacity (920-120) x 2 units
(Time Run)
Amount produced – Amount defects – Amount re-work
%Quality = ----------------------------------------------------------------------- x 100
Amount produced
800 – 10 – 6
= -------------------- x 100 = 98%
800
Overall effectiveness (OEE) = 0.87 x 0.5 x 0.98 x 100 = 42.6 %
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Individual task/class attendance
- As evidence of class attendance, each student must write a one page summary of
Lecture 6 TPM (hand writing).
- Lecture 6 TPM summary can be done in a form of “point form” or “mind mapping”.
- Submit your TPM summary through U-LEARN on Sunday, 12/5/2022.
END
