tpm · 2012-02-01 · tpm – oee calculation tpm metrics: oee (overall equipment effectiveness)...
TRANSCRIPT
TPM
TPM (Total Produc.ve Maintenance) is a philosophy designed to integrate equipment maintenance into the process. The goal of any TPM program is to eliminate losses related with down.me due to equipment maintenance or to the need of keeping equipment producing only good product, as fast as possible with no unplanned down.me. It requires operators to share responsibility for rou.ne machine inspec.on, cleaning, maintenance, and minor repairs.
Source: “Lean Six Sigma Primer”, by the Quality Council of Indiana (QCI).
TPM There are six big losses associated with lack of a TPM program:
1. Equipment failure: breakdowns cause time losses, lower productivity, and quality losses due to defective products.
2. Set up and adjustment: losses due to time spent on set up changes.
3. Idling and minor stoppages: due to defective sensors, parts caught on machine, etc.
4. Reduced speed: the loss between designed and actual operating speeds.
5. Process defects: scrap and quality defects.
6. Reduced yield: product losses from shutdowns and startups.
TPM – OEE Calculation TPM metrics: OEE (Overall Equipment Effectiveness) is the basic indicator used to evaluate TPM. The formulas are: O E E = A v a i l a b i l i t y x Performance Efficiency x Rate of Quality Products
Shift length 8 hours = 480 minutesShort Breaks 2 X 15 min. = 30 minutesMeal Breaks 1 X 30 min. = 30 minutesDown Time 47 minutesIdeal Run Rate 60 pieces per minuteTotal Pieces 19,271 piecesReject Pieces 423 pieces
Production Data
Support Variable Calculation Calculated Data ResultPlanned Production Time Shift Length Breaks 480 -‐ 60 minutes 420 minutes
Operating TimePlanned Production Time -‐ Down Time 420 -‐ 47 minutes 373 minutes
Good PiecesTotal Pieces -‐ Reject Pieces 19,271 -‐ 423 pieces 18,848 pieces
Example
TPM – OEE Calculation OEE = Availability x Performance Efficiency x Rate of Quality Products
Example (continued)
OEE Factor Calcula-on Calculated Data OEE%
Availability Opera.ng Time/Planned Produc.on Time 373/420 minutes 0.8881 (88.81%)
Performance (Total Pieces/Opera.ng Time)/Ideal Run Rate
(19,271 pieces/373 minutes) / 60 pieces per minute 0.8611 (86.11%)
Quality Good Pieces / Total Pieces 18,848 / 19,271 pieces 0.9780 (97.80%)
Overall OEE Availability x Performance x Quality 0.8881 x 0.8611 x 0.9780 0.7479 (74.79%)
OEE Factor World Class
Availably 90.0%
Performance 95.0%
Quality 99.9%
Overall OEE 85.0%
World Class OEE is considered to be 85% or better!!!
Improvement opportunity
TPM
TPM efforts should focus on:
1. Maximizing equipment effectiveness
2. A system of productive maintenance for a machine´s life span.
3. Implementation by departments (including all departments in the company).
4. Involvement of every employee at all levels, top to bottom.
5. Autonomous maintenance by users.
6. Small group activities led by the company.
The company reported the following results after the implementation:
1. Absenteeism was reduced by 50%
2. Suggestions per employee increased from an average of 0.15 to 8 per year
3. Scrap was reduced by 50%
4. Customer rejections were reduced by 90%
5. Set-up times were reduced by 50%
6. Throughput time was reduced by 30%
TPM Effort Example Case Study: Lohr & Bromkamp in Germany, used TPM as the center of their quality initiative. The program began with an overall cleaning of equipment, and all 1800 employees of the company were involved. There were 6 key elements:
1. Autonomous maintenance
2. Eliminating the six big losses
3. 100% production quality
4. A planning system for new machines
5. Training for all operators
6. Increased office efficiency
TPM Example for Offices
A large electronics firm with operations all over the world follows a TPM standard for all company computers. All employees of the organization are scheduled to perform the following maintenance tasks on their computers:
1. Back up: Automatic, performed every Friday afternoon. 2. Antivirus/Anti-spyware software running: To be performed once a week. 3. Old files/unneeded files clean-up: Done manually, monthly. 4. Disk Defragmentation: Done manually, bimonthly. 5. Other diagnostic tool: Done manually, monthly.
TPM Example for Offices – Cont.
Results • Increased life of computers. • Issues are detected and fixed by users. • IT can concentrate on important problems and issues. Culture • If maintenance is not executed as scheduled the
employee can receive a warning/admonition. • Proper computer maintenance is reflected in employee
performance review.