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.
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 to the OEE Factors of Availability, Performance, and Quality.
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 identifying those areas that require resource. 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.
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.
These basic seven pillars of TPM:
Kobetsu Kaizen (Focused Improvement)
Training and Education.
Safety Health Environment (SHE)
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.
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.