VII. Total Productive Maintenance

Question 1

1a. Describe the Total Productive Maintenance (TPM) Tool and its linkage to your customer and business

What measure does Total Productive Maintenance aim to maximize?

Answer 1

Overall Equipment Effectiveness (OEE)

OEE = Availability x Performance x Quality

Availability - Is it running or not?
Performance - Is it running at full speed?
Quality - Is it making good parts?

Question 2

1b. Describe the Total Productive Maintenance (TPM) Tool and its linkage to your customer and business

What are the benefits to Total Productive Maintenance?

Answer 2

From the World-Class Performance Cycle:

• Maximize Flow (Delivery)
• Improve Quality (Quality)
• Eliminate Variation (Cost)

Question 3

2a. Understand the process steps to implement Total Productive Maintenance (TPM) for your area

What are the 5 major steps of applying Total Productive Maintenance (TPM)?

Answer 3

1. Identify and categorize equipment
2. Clean equipment
3. Eliminate sources of contamination
4. Establish standards
5. Implement and monitor

Question 4

2b. Understand the process steps to implement Total Productive Maintenance (TPM) for your area

What are the tasks in TPM Step 1 - Identify and categorize equipment?

Answer 4

1. List all machines
2. Categorize machines
   a. “Category A” - Vital equipment, we stop if broken
   b. “Category B” - Less critical, we slow if broken
   c. “Category C” - Not critical, we’re OK if broken

Question 5

2c. Understand the process steps to implement Total Productive Maintenance (TPM) for your area

What are the tasks in TPM Step 2 - Clean equipment?

Answer 5

1. Clean equipment/environment in order to inspect
2. Inspect equipment/environment in order to detect
3. Detect issues in order to correct
4. Correct issues in order to perfect

Question 6

2d. Understand the process steps to implement Total Productive Maintenance (TPM) for your area

What are the tasks in TPM Step 3 - Eliminate sources of contamination?

Answer 6

1. Fix and prevent sources of contamination
2. Minimize accelerants of deterioration
3. Make areas accessible

Question 7

2e. Understand the process steps to implement Total Productive Maintenance (TPM) for your area

What are the tasks in TPM Step 4 - Establish standards?

Answer 7

1. Create a planned maintenance schedule
2. Establish visuals
3. Create daily walk-around/checklist for the operator
4. Create spare parts list
5. Calculate Overall Equipment Effectiveness (OEE)

Question 8

2f. Understand the process steps to implement Total Productive Maintenance (TPM) for your area

What are the tasks in TPM Step 5 - Implement and monitor?

Answer 8

1. Communicate the process

2. Analyze the results