Definition TPM (Total Productive Maintenance) - What is TPM?

RoxaneB

Change Agent and Data Storyteller
Super Moderator
Equipment Improvement Program (EIP)

We are well on our way to implementing an Equipment Improvement Program (EIP) at our location. Slowly, we are developing "points of inspection" for each piece of equipment and machines. These are areas for the operators to routinely clean and inspect and grease, as necessary.

The Key Equipment Improvement Program (KEIP) then leaves the bigger maintenance jobs available for our maintenance people to do (rather than contract out).

The EIP was implemented concurrently with our 5S program as they complement each other.

In our South American locations, the EIP is called Autonomous Maintenace. We have be trained on the seven steps of a successful EIP - probably a level 3 for us right now, almost ready to go to level 4.

The EIP will be part of how we achieve Integrated Maintenance. This is an improvement process whereby Education/Training, Planned Maintenance, Autonomous Maintenance and Data Management/Analysis are combined to improve the overall state of equipment/process and employee morale.
 

RoxaneB

Change Agent and Data Storyteller
Super Moderator
Marc said:
Sounds like TPM by another name.

I kinda figured that, but the folks down in South America want it to be their system, so we call it by their name...then, because of the union environment we're in, changed it so that no one got overly upset.....a rose by any other name, I guess.
 
S

Swanee

Marc,

I was recently in a TPM facility and was completely blown away. It was the Nissan Dechard Engine Plant. The Tool Crib/Rework Manager gave me a tour of the facility. They are getting something rediculus like 96% OEE, with scheduled downtime! They did a lot of things to notice worn out machine parts like you've mentioned above and the associates were mostly responsible for their own machines. I say mostly because when they had a problem machine everyone goes out to look at it. EVERYONE! Then they decide how to quickly repair the problem. Once it can be quickly brought back to working order they try different ideas to eliminate the problem. After taking the tour with my mouth wide open the manager really threw me for a loop. With a smile he said, "You know...you didn't see a machine today that is newer than twenty years."

Proper TPM is truely a sight to behold.

The company that I work for doesn't have "turn key" machines that look that clean or run that well out of the box. I would be suprised if we achive 60% OEE on what we consider a good running machine.

We have a so called TPM program, but it is basically an excuse to let machines run longer before the "scheduled maintenance".
 
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.
 
A

Alan moss

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
 
L

LumaraC

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. :)
 

Marc

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