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Eight major pillars of TPM - Coggle Diagram
Eight major pillars of TPM
Autonomous Maintenance
Definition
Train operators to close the gap between the maintenance staff, easy to work as one team
Change equipment so the operator can identify abnormal conditions and deterioration before it affects the process (failure)
7 steps to increase operators knowledge, participation and responsibility for their equipment
Conduct general inspection training
Carry out equipment inspection checks
Establish cleaning and lubrication standards
Workplace management and control
Countermeasures for the causes and effects of dirt and dust
Continuous improvement
Perform initial cleaning and inspection
Equipment and process improvement
Objective
maximize efficiency by eliminating waste and manufacturing losses
Manufacturing losses are categorized into 13 big losses
Equipment losses (6)
Downtime loss
Equipment failure / breakdowns
Set-up / adjustments
Speed loss
Minor stopping / idling
Reduced speed
Quality loss
Process errors
Rework / scrap
Manpower losses (4)
Cleaning and checking
Waiting materials
Waiting instructions
Waiting quality confirmation
Material losses (3)
Material yield
Energy losses
Consumable material losses
Overall Equipment Effectiveness (OEE)
Determined by combining the availability and performance of equipment with the quality of parts made
Measures the efficiency of the machine during its planned loading time. Planned downtime does not effect the OEE figure
Overall Equipment Effectiveness = Availability X Performance X Quality Yield
Availability = time available for production - downtime / time available for production
Performance = Ideal cycle time X number of parts produced / operating time
Quality Yield = total numbers of parts produced - defect number / total number of part produced
Machine Performance
Mean time to repair (MTTR) = total downtime/ no of failures
Mean time between failure (MTBF) = total uptime / num of failures
Mean time between failure, mean time to repair, failure rate and reliability equations are key tools for any manufacturing engineer. It allows you to monitor the performance of components or machinery and enables you to plan production, maintain machinery and predict failures.
TPM in administrative and support departments
administrative and support departments can be seen as process plants whose principle tasks are to collect, process, and distribute information.
Process analysis should be applied to streamline information flow
Process Quality Management
Definition: a process for controlling the condition of equipment components that affect variability in product quality
Objective : to set and maintain conditions to accomplish zero defects
Quality rate has a direct correlation with
materials conditions
equipment precision
production methods
process parameters
Planned Maintainace
Objective : establish Preventative and Predictive Maintenance systems for equipment and tooling
Natural life cycle of individual machine elements must be achieved
correct operation
correct set-up
cleaning
lubrication
retightening
feedback and repair of minor defects
quality spare parts
Early Management of new equipment
Objective : establish systems to shorten
new product or equipment development
stat up, commissioning and stabilization time for quality and efficiency
New equipment needs to be :
easy to operate
easy to clean
easy to maintain and reliable
have quick set up times
operate at the lowest life cycle cost
Education and training
TPM is continuous learning process
2 major components
:!: soft skills training : how to work as teams, diversity training and communication skills
:!: technical training : upgrading problem-solving and equipment - related skills
Safety and environmental management
assuring safety and preventing adverse environment impacts are important priorities in any TPM efforts
