TPM
Total Productive Maintenance
What you'll learn
1 2 3 4
Maintenance & SMED: TPM Implementation:
Manufacturing
Comprehensive TPM: Understand various Gain a full guide to
Optimization: Address
Master its 8 pillars, 5 maintenance types implementing TPM in
the Six Big Losses,
key elements, and (Planned, Unplanned, a plant, creating plans
compute OEE, and
how autonomous RCM) and learn (autonomous &
apply World Class
maintenance boosts Single-Minute planned), and
Manufacturing
efficiency. Exchange of Die conducting TPM
Standards.
(SMED). audits.
Karim Besheir
Maintenance Consultant
+201221231959
LinkedIn : [Link]
TPM Course Outline
1. Introduction to Total Productive Maintenance (TPM)
2. The Eight Pillars and The Five Elements of TPM
3. Managing Activities in a TPM Program
4. TPM and OEE (Overall Equipment Effectiveness)
5. TPM Implementation
6. The Role of Individuals in TPM Organizations
7. Levels of Maintenance and Cost Analysis
8. Problem Solving in a TPM Environment with Lean Tools
9. Using 5S Elements for TPM
[Link] Benefits of TPM in a Plant
Introduction to Total Productive Maintenance (TPM)
•What is TPM? A holistic approach to equipment maintenance
that aims to achieve perfect production.
•Core Principles: Zero breakdowns, zero defects, and zero
accidents.
•Evolution of Maintenance: From reactive to proactive and
predictive maintenance.
•Strategic Objectives: Maximizing equipment effectiveness and
efficiency.
•Benefits Overview: Enhanced productivity, cost reduction,
improved safety.
The Eight Pillars and The Five Elements of TPM
• Eight Pillars Overview: Brief introduction to each pillar
(e.g., Autonomous Maintenance, Planned
Maintenance, Quality Maintenance)
• .Key Elements of TPM: Discuss foundational aspects
like management commitment and employee
involvement.
• Interconnectedness: How the pillars and elements
work together for a robust TPM system.
• Building Blocks: Understanding these components is
crucial for successful implementation.
• Holistic Approach: Emphasizing the comprehensive
nature of TPM's structure.
Relation Between the
“Zero Targets” and the
“Pillars”
7
Focused
Improvement
Autonomous
Maintenance
Zero Breakdowns
Planned Maintenance
Training and
Education
Zero Defects
Early Management
Pillars of TPM
5S+1 + Visual Controls
Total Employee Participation
Quality Maintenance
Administrative and
Office
Zero Accidents
Safety, Health, and
Environment
8
Focused
Improvement
Autonomous
Maintenance
Zero Breakdowns
Planned Maintenance
Training and
Education
Zero Defects
Early Management
Pillars of TPM
5S+1 + Visual Controls
Total Employee Participation
Quality Maintenance
Administrative and
Office
Zero Accidents
Safety, Health, and
Environment
9
Focused
Improvement
Autonomous
Maintenance
Zero Breakdowns
Planned Maintenance
Training and
Education
Zero Defects
Early Management
Pillars of TPM
5S+1 + Visual Controls
Total Employee Participation
Quality Maintenance
Administrative and
Office
Zero Accidents
Safety, Health, and
Environment
10
Managing Activities in a TPM Program
• Program Planning: Initial steps for designing and
launching a TPM initiative.
• Role Definition: Clearly assigning responsibilities to
foster effective participation.
• Activity Scheduling: Planning maintenance tasks and
improvement activities.
• Performance Monitoring: Using KPIs to track the
progress and effectiveness of activities.
• Cross-Functional Collaboration: Encouraging teamwork
across departments for seamless execution.
TPM and OEE (Overall Equipment Effectiveness)
• OEE Defined: A critical metric for measuring the true
productivity of equipment.
• The Three Factors of OEE: Availability, Performance, and
Quality Rate.
• Calculating OEE: Understanding how to compute and
interpret the OEE score.
• TPM's Impact on OEE: How TPM practices directly
contribute to higher OEE values.
• Leveraging OEE Data: Using OEE insights to identify
improvement opportunities and prioritize actions.
TPM Implementation Roadmap: From Strategy to Execution
• Implementation Phases: Detailed steps for deploying TPM
across the plant.
• Developing Maintenance Plans: Crafting effective autonomous
and planned maintenance schedules.
• Training and Skill Development: Equipping staff with the
necessary knowledge and tools.
• Pilot Projects: Starting small and scaling up successful TPM
initiatives.
• TPM Audits: Conducting regular assessments to ensure
adherence and identify gaps.
Human Capital in TPM: Empowering Teams and Individuals
• Operator Involvement: The pivotal role of frontline
operators in autonomous maintenance.
• Maintenance Team Evolution: Shifting from reactive to
proactive and problem-solving roles.
• Leadership Engagement: Management's commitment
as a driving force for TPM success.
• Cross-Training: Developing versatile employees
capable of various tasks.
• Culture of Ownership: Fostering a sense of
responsibility and accountability for equipment.
Optimizing Maintenance: Strategies and Cost Implications
• Types of Maintenance: Exploring predictive, preventive, corrective,
and condition-based maintenance.
• Maintenance Cost Analysis: Understanding the financial impact of
different maintenance approaches.
• Life Cycle Costing: Evaluating costs over the entire lifespan of
equipment.
• Balancing Costs and Performance: Finding the optimal maintenance
strategy for efficiency.
• Strategic Sourcing: Optimizing spare parts management and vendor
relationships.
Loss Analysis: Losses in any Business
Losses are like Icebergs;
the more we dig, the
more losses we’ll find
17
16 Big Losses Tree
Material Man Equipment
Defects Ineffective Motions Breakdowns
Poor Administrative Setup and
Rework
Organization Adjustments
Logistics
Non-Standardized Work Small Stops
Losses
Material
Knowledge Management Loss Reduced Speed
Losses
Poor Communication Energy Losses
Low Morale
Lack of KPIs
Loss Contribution Per Department FIXED
No. Main Pillar Type of Loss Maintenance Production Quality Procurement Planning HR
1 Material Defects
2 Rework
3 Logistics Losses
4 Material Losses
5 Man Ineffective Motions
Poor Administrative
6
Organization
7 Non-Standardized Work
8 Knowledge Management Loss
9 Poor Communication
10 Low Morale
11 Lack of KPIs
12 Equipment Breakdowns
13 Setup and Adjustments
14 Small Stops
15 Reduced Speed
16 Energy Losses
Continuous Improvement: Lean Tools for TPM Problem Solving
• Lean Principles Integration: How Lean methodologies enhance
TPM problem-solving.
• Root Cause Analysis: Utilizing tools like the 5 Whys and
Fishbone Diagrams.
• Kaizen Events: Conducting rapid improvement workshops for
specific problems.
• Poka-Yoke (Mistake-Proofing): Implementing solutions to
prevent errors.
• Standardized Work: Ensuring consistency and efficiency in
problem-solving processes.
Workplace Organization: 5S (6S) for TPM Excellence
• The 5S Principles: Sort, Set in Order, Shine, Standardize, Sustain
(Seiri, Seiton, Seiso, Seiketsu, Shitsuke).
• Adding Safety (6S): Incorporating safety as a crucial sixth
element.
• Impact on Autonomous Maintenance: How 5S creates a
foundation for operator-led maintenance.
• Visual Management: Using 5S to make problems and standards
visible.
• Waste Reduction: How a well-organized workplace reduces
various forms of waste.
The TPM Transition
Before After
TPM TPM
22
Key Benefits of TPM Implementation
•Improved Equipment Reliability: Significant reduction in
breakdowns and downtime.
•Reduced Operating Costs: Lower maintenance expenses and
energy consumption.
•Enhanced Productivity and Quality: Consistent output and
fewer defects.
•Safer Work Environment: Proactive identification and
elimination of hazards.
•Increased Employee Engagement: Empowered and motivated
workforce contributing to success.
TPM Effect on Company Performance
OEE
Lead-
Productivity Time Batch
Employee
Sizes
Morale
Costs
Safety
24