Total Productive Maintenance (TPM) is a system of maintaining and improving the integrity of production, safety, and quality systems through the machines, equipment, processes, and employees that add business value to an organization.
The Eight Big Losses
One of the major goals of TPM and OEE programs is to reduce and/or eliminate what are called the Eight Big Losses—the most common causes of equipment-based productivity loss in manufacturing. Capture the Eight Big Losses to gain additional actionable insight into the OEE Factors of Availability, Performance, and Quality.
Overall Equipment Effectiveness (OEE)
OEE (Overall Equipment Effectiveness) is the main performance measure that drives action within Total Productive Maintenance (TPM) and is used by the teams to focus their continuous improvement activities as well as identify those areas that require resources. The preferred OEE calculation is based on the three OEE Factors: Availability, Performance, and Quality. OEE is calculated by multiplying the three OEE factors: Availability, Performance, and Quality.
Role of Plant Managers and Operators
Plant managers, line supervisors, and machine operators work with the equipment day in and day out, and they know what's normal and what's not. A TPM approach gives operators the primary responsibility for taking care of their equipment, including cleaning, inspection, and basic maintenance.
The Seven Pillars of TPM
These basic seven pillars of TPM:
- Autonomous maintenance.
- Kobetsu Kaizen (Focused Improvement)
- Planned Maintenance.
- Quality maintenance.
- Training and Education.
- Office TPM.
- Safety Health Environment (SHE)
Overall Plant Efficiency
Overall plant efficiency is the product of availability, performance rate, and quality products rate and expresses the overall condition of a plant with regard to time, performance, and quality. Overall plant efficiency is used as an index of the degree to which a plant is used to produce added value.
Types of Losses in TPM
01. Shutdown losses:
- Definition: Time lost during production stops due to planned annual shutdown maintenance or periodic maintenance.
- Example: Shutdown maintenance, periodic maintenance, statutory inspection, autonomous inspection, general repair work, etc.
02. Production adjustment losses:
- Definition: Time lost during production adjustments made necessary by supply-demand fluctuations.
- Example: Production-adjustment-related production stops, inventory-adjustments-related production stops, etc.
03. Equipment failure losses:
- Definition: Time lost during sudden production stops occurring when equipment loses its specified functions.
- Example: Broken pump, burnt motor, damaged bearings, broken shaft.
04. Process failure losses:
- Definition: Time lost during plant shutdown caused by changes in chemical or physical characteristics of materials handled, operation errors, disturbances, etc.
- Example: Leaks, spills, blocks, corrosion, erosion, scattered powder, operation error.
05. Normal Production Loss:
- Definition: Losses occurring at plant startup, production stop, and changeover.
- Example: Production rate decreases during warm-up after start-up, cool down before production stop or changeover.
06. Abnormal production loss:
- Definition: Production losses caused by production rate decreases due to malfunctioning or abnormalities in the plant.
- Example: Low-load operation, low-speed operation, and operation below the standard production rate.
07. Quality defect losses:
- Definition: Losses due to the production of defectives and physical losses from scrap, losses from product downgrading.
- Example: Physical and time losses caused by the production of products deviating from quality standards.
08. Reprocessing losses:
- Definition: Recycling losses due to sending defectives through a previous process.
- Example: Recycling by passing through earlier processes to make defectives at hand processing stage into acceptable products.
From India, Pune
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3The Eight Big Losses
One of the major goals of TPM and OEE programs is to reduce and/or eliminate what are called the Eight Big Losses—the most common causes of equipment-based productivity loss in manufacturing. Capture the Eight Big Losses to gain additional actionable insight into the OEE Factors of Availability, Performance, and Quality.
Overall Equipment Effectiveness (OEE)
OEE (Overall Equipment Effectiveness) is the main performance measure that drives action within Total Productive Maintenance (TPM) and is used by the teams to focus their continuous improvement activities as well as identify those areas that require resources. The preferred OEE calculation is based on the three OEE Factors: Availability, Performance, and Quality. OEE is calculated by multiplying the three OEE factors: Availability, Performance, and Quality.
Role of Plant Managers and Operators
Plant managers, line supervisors, and machine operators work with the equipment day in and day out, and they know what's normal and what's not. A TPM approach gives operators the primary responsibility for taking care of their equipment, including cleaning, inspection, and basic maintenance.
The Seven Pillars of TPM
These basic seven pillars of TPM:
- Autonomous maintenance.
- Kobetsu Kaizen (Focused Improvement)
- Planned Maintenance.
- Quality maintenance.
- Training and Education.
- Office TPM.
- Safety Health Environment (SHE)
Overall Plant Efficiency
Overall plant efficiency is the product of availability, performance rate, and quality products rate and expresses the overall condition of a plant with regard to time, performance, and quality. Overall plant efficiency is used as an index of the degree to which a plant is used to produce added value.
Types of Losses in TPM
01. Shutdown losses:
- Definition: Time lost during production stops due to planned annual shutdown maintenance or periodic maintenance.
- Example: Shutdown maintenance, periodic maintenance, statutory inspection, autonomous inspection, general repair work, etc.
02. Production adjustment losses:
- Definition: Time lost during production adjustments made necessary by supply-demand fluctuations.
- Example: Production-adjustment-related production stops, inventory-adjustments-related production stops, etc.
03. Equipment failure losses:
- Definition: Time lost during sudden production stops occurring when equipment loses its specified functions.
- Example: Broken pump, burnt motor, damaged bearings, broken shaft.
04. Process failure losses:
- Definition: Time lost during plant shutdown caused by changes in chemical or physical characteristics of materials handled, operation errors, disturbances, etc.
- Example: Leaks, spills, blocks, corrosion, erosion, scattered powder, operation error.
05. Normal Production Loss:
- Definition: Losses occurring at plant startup, production stop, and changeover.
- Example: Production rate decreases during warm-up after start-up, cool down before production stop or changeover.
06. Abnormal production loss:
- Definition: Production losses caused by production rate decreases due to malfunctioning or abnormalities in the plant.
- Example: Low-load operation, low-speed operation, and operation below the standard production rate.
07. Quality defect losses:
- Definition: Losses due to the production of defectives and physical losses from scrap, losses from product downgrading.
- Example: Physical and time losses caused by the production of products deviating from quality standards.
08. Reprocessing losses:
- Definition: Recycling losses due to sending defectives through a previous process.
- Example: Recycling by passing through earlier processes to make defectives at hand processing stage into acceptable products.
From India, Pune
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