TPM
TPM - Total Productive Maintenance and preventive maintenance. This article gets a little touch on the chapter of Total Productive Maintenance as well as preventive maintenance. It might be confusing as everywhere in the lean world productive maintenance is set but also preventive maintenance is in the chapter.
First things first - lets define productive maintenance (TPM)
TPM (Total Productive Maintenance) is a systematic approach to the comprehensive preventive maintenance of machines, equipment and plants (M.E.P.)
The targets:
The unplanned technical failures are minimized/eliminated
Technical availability > 95% of M.E.P., where economically reasonable, is achieved
More than 80% of the total maintenance time is planned preventive maintenance
TPM is used in all M.E.P.
Spare parts are available in the right quantity when needed
Key elements:
Procedure for introduction
Maintenance methods
Technical availability
Work organization
Qualification Operator/Service
Spare parts
Influence on M.E.P. manufacturers
Documentation
Development and application of methods for damage - early detection
Key Performance Indicators (KPI)
Availability indicator, overall plant efficiency (OPE)
Key figures of the TPM assessment sheet
Maintenance costs
Service - Reaction target
For your self assessment we will mention now the 5 levels of fulfillment for some key parts of TPM and preventive maintenance.
Levels of fulfillment - procedures and introduction
Level 1
No systematics, preventive maintenance as required.
Level 2
TPM - implementation (stages 1-3) for bottleneck or output relevant machines, planned alternative production.
Level 3
TPM - implementation (stages 1-3) for all “A” machines and associated supply facilities, advance and emergency strategies are available.
Level 4
TPM implementation (stages 1-3) for all “B” machines incl. associated supply facilities and stages 4-5 for all ”A” machines; pre-run and emergency strategies are available.
Level 5
TPM implementation (level 6) in all M.E.P., creating a lead time and having emergency strategies in place.
Fulfillment levels of Maintenance Methods
Level 1
Repair > 90% (crash, planned); preventive maintenance (experience-based, time-dependent, preventive) <10%.
Level 2
Repair < 80% (crash, planned); preventive maintenance >20% (experience-based, time-dependent, preventive).
Level 3
Repair < 50% (crash, planned); preventive maintenance >50% (experience-based, time-dependent, preventive).
Level 4
Repair < 30% (crash, planned); preventive >70% maintenance (experience-based, time-dependent, preventive).
Level 5
Repair < 20% (crash, planned); preventive >80% maintenance (experience-based, time-dependent, preventive).
Technical availability
Level 1
Approx. 80 %, high waiting times, line stops.
Level 2
> 80 %, less waiting times, but considerable additional costs due to alternative production.
Level 3
Improvement to > 90 %, for “A” machines. No waiting times due to planned maintenance.
Level 4
Increase “A“ machines > 90 %, “B” machines: + 5 %, where economically reasonable. No waiting times due to planned maintenance.
Level 5
> 95 %, where economically reasonable, no waiting times due to planned maintenance.
Levels of Work organization
Level 1
Central service, specialist team. Operators not included. All cleaning and maintenance work is carried out by the area service.
Level 2
Area service by team of specialists and simple maintenance and cleaning work carried out by the operator.
Level 3
Area service by specialists and execution of necessary activities according to maintenance plans prepared by operators and preventive maintenance (PM) - plans of service.
Level 4
Specialists available for everyone at short notice (cross-domain deployment). Operating staff actively supports the specialists.
Level 5
Comprehensive inspection, maintenance, repair of the equipment by a team (operators and specialists from inside and outside).
Qualification of operator services
Level 1
No operator qualification. Specialists for machine groups and individual fields.
Level 2
Operator qualification according to TPM implementation (step-by-step plan) Specialists create and work through PM plans. Qualification across machine groups.
Level 3
Further qualification of the specialists as trainers. Like level 2 and further additional qualification, e.g. hybrid systems + new equipment.
Level 4
Further qualification of the specialists as trainers. Specialists with hybrid training.
Level 5
Further qualification of the specialists as trainers.
Spare Parts Management
Level 1
Unregistered spare parts in small unstructured warehouses based on the experience of maintenance staff. Call on demand and not recorded.
Level 2
Spare parts planning and systematization of the warehouse (IT technical recording).
Level 3
As under level 2 and classification and reference source release (standardization).
Level 4
Spare parts for “A” machines are available in the right quantity in case of need.
Level 5
Spare parts available in the correct quantity and when required cross-company consignment stock.
Influence on machinery, equipment and plants (MEP)
Level 1
No data recording on availability or failures.
Level 2
Use of the standard documentation of the M.E.P. manufacturer.
Level 3
Display of the overall plant efficiency at “A“ machines, exchange of information with M.E.P. – manufacturers.
Level 4
Reporting of the overall plant efficiency at all plants. M.E.P. - Manufacturer uses TPM experience systematically.
Level 5
Networking machine, service and M.E.P. - manufacturer. Use of experience for own further developments of standard machines (competitive advantage).
Documentation
Level 1
No or outdated maintenance plans, no standards.
Level 2
Maintenance plans and individual standards are available.
Level 3
In the TPM - Workshop maintenance, cleaning and preventive maintenance plans including standard lines for the service were worked out. Use the flow of information internally and to manufacturers + use the manufacturer's experience.
Level 4
Intervals for maintenance, cleaning and preventive maintenance are standardized, documented and coordinated.
Level 5
Flexible planning system to coordinate all maintenance activities.
Preventive measures levels of fulfillment
Level 1
Technical individual solutions available (sensors).
Level 2
Individual solutions for “A” machines are available.
Level 3
Classifications for preventive systems have been developed.
Level 4
Preventive systems are introduced for “A” machines.
Level 5
Preventive systems themselves - systems are where it makes economic sense to have them.
