Mantenimiento

Total Productive Maintenance

What We Will Review...
The Origins of TPM. Why is it the foundation of Lean Manufacturing? Equipment Life Cycle The Original and the Human Structure of TPM Losses: Human Resources, Energy and supplies, Equipment
related

OEE Overall Equipment Effectiveness The 5Ss Discipline
Workplace Organization and the Value of Visual Controls

The Training Process TheCore of TPM: Autonomous Maintenance, One Point Lessons Maintenance:
Preventive Planned Prevented or Avoided

Root Cause Analysis The Implementation Process Coordinator’s responsibilities Visual Systems

Trends…
Pric e

pe m Co

n tio ti
Final Crisis

Profit Margin

Cost

Lean Manufacturing through Kaizen Events contributes to reduce wastes and therefore the cost, (The onlycontrollable factor).
World War II Globalization 3rd. Millennium

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Based on Dr. W. E. Deming’s statistical analysis, TPM is a Process to Identify and Eliminate Costs for the Whole Life Cycle of the Equipment...

Design
Build, Test, Tryout Install Startup
Stage to improve and extend

Operate, utilize (Useful life)
Remove, dispose

Equipment LifeCycle
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Traditional Equipment Life Cycle without T.P.M.
100%
Short Useful Life

Failure Incidence Higher Cost Of Operation

0%

Initial Use Daily Use Deteriorated
Time

The Equipment Life Cycle With T.P.M.
100%
Productive Life of the equipment is considerably extended

Failure Incidence

0%

Design-Test

Daily Use
TimeStructure of TPM:
Any weakness in the elements would keep it from performing

TPM
Preventive Maintenance

Planned Maintenance

Maintenance Projects

Autonomous Maintenance

Reliability Centered Maintenance

Education – Training – Management Support – Culturization The 5 S Philosophy – Work Place Organization & Control
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Structure of TPM:Total Productive Management From the Human Point of View

TPM
Mutual Support and Innovative Leadership Structure

Coordinated Efforts to Understand and Preserve the Equipment

Education – Training – Management Support – Culturization The 5 S Philosophy – Work Place Organization & Control Applied Human Relations Improved Multi-level Communication Motivation and Negotiation Skills
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Leadership and Authority
One of the most important advantages of TPM is the improvement in the Leadership environment People at different levels will increase their participation in decision making processes, relieving management from having to take care of the most minimal detail Only in a true leadership environment can we achieve maximum cooperationPossible Losses in Human Resources
Do we consider each employee as a person? Or do we hire them as if they were a mechanic device? We often waste very valuable features:
They are intelligent They are creative, they have brilliant ideas They are objective, imaginative They can develop the right positive attitude

With a good communication we can take advantage of all these good characteristics.Communication is The Key!
In order to benefit from other people’s cooperation we should become better communicators. When we communicate well, we will be able to help people motivate towards our positive goals.
They will have the opportunity to discover how their cooperation will generate benefits for them

When we have disagreements, our good communication skills will help us achievenegotiation
When two people have different opinions, they both are right. They base their opinions on their own knowledge and experience

Types of Losses on Equipment
Major Breakdowns Adjustments, Tool Setups Minor Stoppages Lower performance than expected Wasted material-reworks-returns Shift or model start-up yields

Possible Wastes due to the Equipment
Material Direct Indirect Variations...