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TPM (Total Productive Maintenance) - What is TPM?
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TPM (Total Productive Maintenance) - What is TPM?
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  Post Number #25  
Old 9th July 2004, 01:28 PM
Icy Mountain's Avatar
Icy Mountain

Total Posts: 902
Another example

At a nameless auto manufacturer:
Every 15-20 minutes, associates spent 5 minutes climbing into the automated welding lines (2 lines/128 robots each line) and filing the welding tips back to 8mm with a hand file. (Cycle time produced ~1 car per minute).

This was followed by 3-5 minutes of chaos every 3rd or 4th stop. Current density is defined by the amount of current passed through the area of the weld tip. Too high, the weld "blows out". Or rough cut the tip and it sticks to the part, pulling the tip, spraying water everywhere, machine shutdown, new tip, etc. (this will be important in a minute).

Said mfg. spent over $2 million US on the following:
Automatic tip "dresser" (installed) for all 256 robots.
Additional robot movement program to find the dresser.
New weld timer with step-up (programmable) current for 256 robots.
New programming for 32 different Programmable Logic Controllers for the robots (count the cycles, step up the current every 5 cycles to adjust for tips flattening out as they wear, every 15 cycles make the robots clean their tips, reset the weld current back to the beginning).
Testing each system as it was installed for safety/performance/interference/etc.

Savings (conservatively based on an estimated downtime cost of $10K per minute)
15 minutes per hour x 8 hours per shift x 2 shifts per day x 250 days per year x that $10K per minute = $40 million (and that's only one line).

Results varied, but, worst case was an additional 80 welded bodies per shift per line per day. That's another 320 bodies a day! Without adding personnel, work time, or plant space.

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  Post Number #26  
Old 21st July 2006, 11:19 AM
Alan moss

Total Posts: 2
Re: What Is TPM (Total Productive Maintenance)?

hi my name is alan moss . i am just starting up atpm programe at my firm i woul be very greatful if any one can send me some templets of tpm schudles and counter measure shhet so i can get some ideas pleaes

many thanks in advance

alan moss
  Post Number #27  
Old 15th August 2016, 03:01 AM

Total Posts: 16
Re: TPM (Total Productive Maintenance) - What is TPM?

I was curious when reading this topic and got more excited when everyone in this thread start sharing their working experience involving TPM.

It is fun and good to read it as I'm a beginner in the maintenance world.

I do involve with TPM but from my point of view; the TPM we carry out was just to fulfill audit requirement.
And I was surprised about how the Motorola handle their TPM very detail and involve everybody.
I do sometimes ask my self, do we need to be very detail about TPM until we reach for every small parts
(because our TPM only touch the big part/the visible part that can be see from outside)

Hopefully this thread will be going on by people sharing their experience in their working field.
Looking forward to learn more.
  Post Number #28  
Old 15th August 2016, 04:13 AM
Marc's Avatar

Total Posts: 26,589
I Say... Re: What Is TPM (Total Productive Maintenance)?

Here is an oldie: TPM - Total Productive Maintenance

This discussion is pretty good: Top Three Reasons why TPM (Total Productive Maintenance) Initiatives Fail

Planned Maintenance

Wikipedia reference-linkTotal_productive_maintenance
Attached Files: 1. Scan for viruses before opening, 2. Please report any 'bad' files by Reporting this post, 3. Use at your Own Risk.
File Type: pdf TPM - Total Productive Maintenance.pdf (423.1 KB, 291 views)
File Type: docx TPM - Total Productive Maintenance.docx (15.6 KB, 215 views)
File Type: ppt TPM KIB.ppt (230.0 KB, 87 views)
File Type: ppt TPM - Total Productive Manufacturing.ppt (1.03 MB, 126 views)
Thanks to Marc for your informative Post and/or Attachment!
  Post Number #29  
Old 16th March 2018, 12:11 PM
Marc's Avatar

Total Posts: 26,589
Re: TPM (Total Productive Maintenance) - What is TPM?

A quick "bump" to remind folks about TPM.

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