| 1 – What is Total Productive Maintenance?
Total Productive Maintenance (TPM) is a process to maximize the productivity of your equipment for its entire life. TPM fosters an environment where improvement efforts in Safety, Quality, Delivery, Cost and Creativity are encouraged, through the participation of all employees.
The goal of TPM is to maximize your Overall Equipment Effectiveness(OEE) and to reduce equipment downtime to zero while improving quality and capacity.
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3 – Successes
A tool manufacturer implemented the TPM process to improve the productivity of their equipment. They were implementing lean, attempting to flow their parts, but were having difficulty because of the poor uptime (capacity) of their equipment. Within 18 months they saw a 15% increase in equipment productivity. What they were not expecting was a $1,200,000 reduction in their maintenance budget (repair parts), including $50,000 reduction in oil usage (reduced leaks), $56,000 reduction in water usage (leaks and modifications), and $57,000 reduction in contract maintenance.
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2 – Benefits
Typical manufacturing operations have experienced improvements in the following areas in a relatively short period of time, (6-12) months, through the implementation of TPM:
- Overall Equipment Effectiveness (capacity) improvement of 25-65%
- Quality improvement of 25-50%
- Maintenance expenditure reductions of 10-50%
- Percent Planned vs. Unplanned maintenance increase of 10-60%
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4 – Course Description
LE207: Total Productive Maintenance (TPM)
Learn about Overall Equipment Effectiveness (OEE) and how it is related to capacity. Learn how to apply 5S techniques on your equipment and see the tenfold effect they have. Learn about the six major equipment related losses – how to find and eliminate them. Learn what causes 75% of equipment breakdowns. TPM principles will be demonstrated – and you will be able to apply the techniques as we simulate equipment in our classroom. By the end of the day you’ll experience how these techniques achieve dramatic improvements in uptime and increased equipment effectiveness.
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