TPM (Total Productive Maintenance) as a waste elimination tool

Today we discuss about Total productive maintenance(TPM) as a waste elimination tool.

TPM defined as TPM (Total Productive Maintenance) is a maintenance philosophy designed to integrate equipment maintenance into the manufacturing process.

The goal of any TPM program is to eliminate losses tied to equipment maintenance or, in other words, keep equipment producing only good product, as fast as possible with no unplanned downtime. The unique feature of TPM is Autonomous Maintenance.

Autonomous Maintenance defined as Machine adjustments made by their operators who are deemed to have unique knowledge about the machines. It is a principal component of total productivity maintenance (TPM).

In TPM mainly focus 16 losses and eliminate from the process.16 losses’ are:

A Seven major losses that impede overall equipment efficiency

1 Failure losses (Breakdown)
       Losses due to failures. Types of failures include sporadic function-stopping failures, and function-reduction failures in which the function of the equipment drops below
Normal levels.

2 Set up and adjustment losses
Stoppage losses that accompany set-up changeovers

3 Cutting blade change losses
 Stoppage losses caused by changing the cutting blade due to breakage, or caused by changing the cutting blade when the service life of the grinding stone, cutter or bite has been reached.

4 Start-up losses
 When starting production, the losses that arise until equipment start-up, running-in and production processing conditions stabilize.

5 Minor stoppage and idling losses
Losses that occur when the equipment temporarily stops or idles due to sensor actuation or jamming of the work.  The equipment will operate normally through simple measures (removal of the work and resetting).

6 Speed losses
Losses due to actual operating speed falling below the designed speed of the equipment.

7 Defect & rework loss
 Losses due to defects & reworking.
 Losses that impede equipment loading time

8 Shutdown (SD) losses
 Losses that arise from planned equipment stoppages at the production planning level in order to perform periodic inspection and statutory inspection.

Five Major losses that impede workers efficiency

9 Management losses
 Waiting losses that are caused by management, such as waiting for materials, waiting for a dolly, waiting for tools, waiting for instructions etc.

10 Motion losses
 Man-hour losses arising from differences in skills involved in etc.

11 Line organization losses
 Idle time losses when waiting for multiple processes or multiple platforms.

12 Distribution losses
 Distribution man-hour losses due to transport of materials, products (processed products) and dollies.

13 Measurement and  adjustment losses
Work losses from frequent measurement and adjustment in order to prevent the occurrence and outflow of quality defects.

Three major losses that impede efficient use of production subsidiary resources

14 Energy losses
 Losses due to ineffective utilization of input energy (electric, gas, fuel oil, etc) in processing.

15 Die, jig and tool losses
 Financial losses (expenses incurred in production, regarding renitriding, etc.) which occur with production or repairs of dies, jigs and tolls due to aging beyond services life or breakage.

16 Yield losses
 Material losses due to differences in the weight of the input materials and the weight of the quality products.