1. The TPM Total Productive Maintenance BY SHAILENDRA DAF

6. 4. Eight major pillars of TPM Education and training Safety and environmental management Autonomous Maintenance Planned Maintenance Equipment and process improvement Early management of new equipment Process quality management TPM in the office

9. 4. Eight major pillars of TPM 4.2. Equipment and process improvement 4.2.1. Equipment losses Downtime loss Speed loss Quality loss Equipment failure / breakdowns Set-up / adjustments Minor stopping / idling Reduced speed Process errors Rework / scrap

10. 4. Eight major pillars of TPM 4.2. Equipment and process improvement 4.2.2. Manpower and material losses Manpower losses Material losses Cleaning and checking Waiting instructions Waiting quality confirmation Material yield Energy losses Waiting materials Consumable material losses

12. 4. Eight major pillars of TPM 4.2. Equipment and process improvement 4.2.3 Overall Equipment Effectiveness (OEE) Overall Equipment Effectiveness = Availability x Performance x Quality Yield Availability Downtime loss Speed loss Performance Quality Yield Quality loss

13. 4. Eight major pillars of TPM 4.2. Equipment and process improvement 4.2.3 Overall Equipment Effectiveness (OEE) Overall Equipment Effectiveness = Availability x Performance x Quality Yield Availability = time available for production - downtime time available for production Performance = ideal cycle time x number of parts produced operating time Quality Yield = total number of parts produced - defect number total number of parts produced

20. 5. TPM Implementation 12 steps Preparation Kick-off Implementation Announcement to introduce TPM Introductory education campaign for the workforce TPM Promotion (special committees) Establish basic TPM policies and goals Preparation and Formulation of a master plan Develop an equipment management program Develop a planned maintenance program Develop an autonomous maintenance program Increase skills of production and maintenance personnel Perfect TPM implementation and raise TPM levels Stabilization Develop early equipment management program Invite customers, affiliated companies and subcontractors

27. WHY FAILURE OF TPM

30. Regression result for Operational Strategy and Extent of TPM Implementation General Training Top Executive Commitment Maintenance Training Supportive TPM environment Workplace Improvement 0.205 0.040 0.271 0.071 0.197 R2 Adj. R2 F Value 0.32 0.28 8.47**

31. Two stage regression analyses with Human-oriented strategy entered first in the model Model 1: Supportive TPM environment, General Training, Maintenance Training, Top Executive Commitment Model 2: Supportive TPM environment, General Training, Maintenance Training, Top Executive Commitment, Workplace Improvement Dependent variable: Extent of TPM. R R2 Adjusted R2 Δ R2 F Model 1: Model 2: 0.54 0.29 0.26 0.29 9.40 0.57 0.32 0.28 0.03 3.66

32. Two stage regression analyses with Process-oriented strategy entered first in the model Model 1 : Workplace Improvement Model 2: Workplace Improvement, Supportive TPM environment, General Training, Maintenance Training, Top Executive Commitment, Dependent variable: Extent of TPM. R R2 Adjusted R2 Δ R2 F Model 1: Model 2: 0.41 0.17 0.16 0.17 18.64 0.57 0.32 0.28 0.15 5.12

35. Questions ?