What is Total Productive MaintenanceWord文档格式.docx

What is Total Productive MaintenanceWord文档格式.docx

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∙Producealowbatchquantityattheearliestpossibletime.

∙Goodssendtothecustomersmustbenondefective.

SimilaritiesanddifferencesbetweenTQMandTPM:

TheTPMprogramcloselyresemblesthepopularTotalQualityManagement（TQM）program.Manyofthetoolssuchasemployeeempowerment,benchmarking,documentation,etc.usedinTQMareusedtoimplementandoptimizeTPM.Followingarethesimilaritiesbetweenthetwo.

1.Totalcommitmenttotheprogrambyupperlevelmanagementisrequiredinbothprogrammes

2.Employeesmustbeempoweredtoinitiatecorrectiveaction,and

3.AlongrangeoutlookmustbeacceptedasTPMmaytakeayearormoretoimplementandisanon-goingprocess.Changesinemployeemind-settowardtheirjobresponsibilitiesmusttakeplaceaswell.

ThedifferencesbetweenTQMandTPMissummarizedbelow.

Category

TQM

TPM

Object

Quality（Outputandeffects）

Equipment（Inputandcause）

Mainsofattaininggoal

Systematizethemanagement.Itissoftwareoriented

Employeesparticipationanditishardwareoriented

Target

QualityforPPM

Eliminationoflossesandwastes.

Typesofmaintenance:

1.Breakdownmaintenance:

Itmeansthatpeoplewaitsuntilequipmentfailsandrepairit.Suchathingcouldbeusedwhentheequipmentfailuredoesnotsignificantlyaffecttheoperationorproductionorgenerateanysignificantlossotherthanrepaircost.

2.Preventivemaintenance（1951）:

Itisadailymaintenance（cleaning,inspection,oilingandre-tightening）,designtoretainthehealthyconditionofequipmentandpreventfailurethroughthepreventionofdeterioration,periodicinspectionorequipmentconditiondiagnosis,tomeasuredeterioration.Itisfurtherdividedintoperiodicmaintenanceandpredictivemaintenance.Justlikehumanlifeisextendedbypreventivemedicine,theequipmentservicelifecanbeprolongedbydoingpreventivemaintenance.

2a.Periodicmaintenance（Timebasedmaintenance-TBM）:

Timebasedmaintenanceconsistsofperiodicallyinspecting,servicingandcleaningequipmentandreplacingpartstopreventsuddenfailureandprocessproblems.

2b.Predictivemaintenance:

Thisisamethodinwhichtheservicelifeofimportantpartispredictedbasedoninspectionordiagnosis,inordertousethepartstothelimitoftheirservicelife.Comparedtoperiodicmaintenance,predictivemaintenanceisconditionbasedmaintenance.Itmanagestrendvalues,bymeasuringandanalyzingdataaboutdeteriorationandemploysasurveillancesystem,designedtomonitorconditionsthroughanon-linesystem.

3.Correctivemaintenance（1957）:

Itimprovesequipmentanditscomponentssothatpreventivemaintenancecanbecarriedoutreliably.Equipmentwithdesignweaknessmustberedesignedtoimprovereliabilityorimprovingmaintainability

4.Maintenanceprevention（1960）:

Itindicatesthedesignofanewequipment.Weaknessofcurrentmachinesaresufficientlystudied（onsiteinformationleadingtofailureprevention,easiermaintenanceandpreventsofdefects,safetyandeaseofmanufacturing）andareincorporatedbeforecommissioninganewequipment.

TPM-History:

TPMisainnovativeJapaneseconcept.TheoriginofTPMcanbetracedbackto1951whenpreventivemaintenancewasintroducedinJapan.HowevertheconceptofpreventivemaintenancewastakenfromUSA.Nippondensowasthefirstcompanytointroduceplantwidepreventivemaintenancein1960.Preventivemaintenanceistheconceptwherein,operatorsproducedgoodsusingmachinesandthemaintenancegroupwasdedicatedwithworkofmaintainingthosemachines,howeverwiththeautomationofNippondenso,maintenancebecameaproblemasmoremaintenancepersonnelwererequired.Sothemanagementdecidedthattheroutinemaintenanceofequipmentwouldbecarriedoutbytheoperators.（ThisisAutonomousmaintenance,oneofthefeaturesofTPM）.Maintenancegrouptookuponlyessentialmaintenanceworks.

ThusNippondensowhichalreadyfollowedpreventivemaintenancealsoaddedAutonomousmaintenancedonebyproductionoperators.Themaintenancecrewwentintheequipmentmodificationforimprovingreliability.Themodificationsweremadeorincorporatedinnewequipment.Thisleadtomaintenanceprevention.ThuspreventivemaintenancealongwithMaintenancepreventionandMaintainabilityImprovementgavebirthtoProductivemaintenance.Theaimofproductivemaintenancewastomaximizeplantandequipmenteffectivenesstoachieveoptimumlifecyclecostofproductionequipment.

BythenNipponDensohadmadequalitycircles,involvingtheemployeesparticipation.ThusallemployeestookpartinimplementingProductivemaintenance.BasedonthesedevelopmentsNippondensowasawardedthedistinguishedplantprizefordevelopingandimplementingTPM,bytheJapaneseInstituteofPlantEngineers（JIPE）.ThusNippondensooftheToyotagroupbecamethefirstcompanytoobtaintheTPMcertification.

TPMTargets:

P

ObtainMinimum80%OPE.

ObtainMinimum90%OEE（OverallEquipmentEffectiveness）

Runthemachinesevenduringlunch.（Lunchisforoperatorsandnotformachines!

）

Q

Operateinamanner,sothattherearenocustomercomplaints.

C

Reducethemanufacturingcostby30%.

D

Achieve100%successindeliveringthegoodsasrequiredbythecustomer.

S

Maintainaaccidentfreeenvironment.

M

Increasethesuggestionsby3times.DevelopMulti-skilledandflexibleworkers.

MotivesofTPM

1.Adoptionoflifecycleapproachforimprovingtheoverallperformanceofproductionequipment.

2.Improvingproductivitybyhighlymotivatedworkerswhichisachievedbyjobenlargement.

3.Theuseofvoluntarysmallgroupactivitiesforidentifyingthecauseoffailure,possibleplantandequipmentmodifications.

UniquenessofTPM

ThemajordifferencebetweenTPMandotherconceptsisthattheoperatorsarealsomadetoinvolveinthemaintenanceprocess.Theconceptof"

I（Productionoperators）Operate,You（Maintenancedepartment）fix"

isnotfollowed.

TPMObjectives

1.AchieveZeroDefects,ZeroBreakdownandZeroaccidentsinallfunctionalareasoftheorganization.

2.Involvepeopleinalllevelsoforganization.

3.FormdifferentteamstoreducedefectsandSelfMaintenance.

DirectbenefitsofTPM

1.IncreaseproductivityandOPE（OverallPlantEfficiency）by1.5or2times.

2.Rectifycustomercomplaints.

3.Reducethemanufacturingcostby30%.

4.Satisfythecustomersneedsby100%（Deliveringtherightquantityattherighttime,intherequiredquality.）

5.Reduceaccidents.

6.Followpollutioncontrolmeasures.

IndirectbenefitsofTPM

1.Higherconfidencelevelamongtheemployees.

2.Keeptheworkplaceclean,neatandattractive.

3.Favorablechangeintheattitudeoftheoperators.

4.Achievegoalsbyworkingasteam.

5.Horizontaldeploymentofanewconceptinallareasoftheorganization.

6.Shareknowledgeandexperience.

7.Theworkersgetafeelingofowningthemachine.

OEE（OverallEquipmentEfficiency）:

OEE=AxPExQ

A-Availabilityofthemachine.Availabilityisproportionoftimemachineisactuallyavailableoutoftimeitshouldbeavailable.

A=（MTBF-MTTR）/MTBF.

MTBF-MeanTimeBetweenFailures=（TotalRunningTime）/NumberofFailures.

MTTR-MeanTimeToRepair.

PE-PerformanceEfficiency.ItisgivenbyREXSE.

Rateefficiency（RE）:

Actualaveragecycletimeisslowerthandesigncycletimebecauseofjams,etc.Outputisreducedbecauseofjams

Speedefficiency（SE）:

Actualcycletimeisslowerthandesigncycletimemachineoutputisreducedbecauseitisrunningatreducedspeed.

Q-Referstoqualityrate.Whichispercentageofgoodpartsoutoftotalproducedsometimescalled"

yield"

.

StepsinintroductionofTPMinaorganization:

StepA-PREPARATORYSTAGE:

STEP1-AnnouncementbyManagementtoallaboutTPMintroductionintheorganization:

Properunderstanding,commitmentandactiveinvolvementofthetopmanagementinneededforthisstep.Seniormanagementshouldhaveawarenessprogrammes,afterwhichannouncementismadetoall.Publishitinthehousemagazineandputitinthenoticeboard.Sendalettertoallconcernedindividualsifrequired.

STEP2-InitialeducationandpropagandaforTPM:

Trainingistobedonebasedontheneed.Someneedintensivetrainingandsomejustanawareness.TakepeoplewhomatterstoplaceswhereTPMalreadysuccessfullyimplemented.

STEP3-SettingupTPManddepartmentalcommittees:

TPMincludesimprovement,autonomousmaintenance,qualitymaintenanceetc.,aspartofit.Whencommitteesaresetupitshouldtakecareofallthoseneeds.

STEP4-Establishin