Total Productive Maintenance

Increase capacity. Improve quality. Reduce operating costs and capital expenditures by increasing your equipment's life expectancy with Total Productive Maintenance.

House of Lean

Benefits of TPM

• Increased Capacity of 25% to 65%
• Quality improvements of 25% to 50%
• Reduced Maintenance Cost of 10% to 50%
• Reduction in unplanned maintenance hours of 10% to 60%

Total Productive Maintenance (TPM) is a process designed to help you achieve the maximum productivity and extend the life of your equipment. TPM fosters an environment where improvements 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 unplanned equipment downtime to zero while improving quality and capacity.

The Process

A typical sequence of implementing TPM follows:

• The first step is to calculate Overall Equipment Effectiveness (OEE). This is accomplished by collecting OEE data, analyzing the data and prioritizing improvement opportunities. OEE is categorized into three components:
  • Availability- Machine downtime for maintenance (both planned and unplanned)and changeover time
  • Performance efficiency, i.e. % of designated speed and continuous production
  • Rate of quality- product quality (defects/ rework) and process repeatability
  • Based on the above, OEE=availability X performance efficiency X rate of quality
• The second step is to maximize equipment capacity based on the OEE and the prioritized list of improvement opportunities such as:
  • Reduce machine idling and minor stoppages
  • Eliminate defects and rework
  • Identify relationships between losses
  • Reduce machine changeover time
  • Eliminate machine breakdowns
  • Address machine start up losses and reduced machine speed issues
• The final step is to implement the TPM process which includes the following elements:
  • Develop a plan that includes the selection of critical equipment, establishing a baseline and integrating the business plan
  • Start the process by introducing 5S and visual controls, countermeasures and preventative maintenance checklists
  • Deploy the plan and improvements
  • Document the results
  • Evaluate results and pursue continuous improvement

Our Experience and Track Record

Insyte Consulting has Western New York's largest and most diverse staff of Lean Six Sigma (LSS) manufacturing experts — all with extensive hands-on, industry experience. We have helped WNY companies improve operations
using lean manufacturing methodologies for over 25 years. Insyte has worked successfully with more WNY companies using these techniques than any other consulting organization. We welcome the opportunity to discuss your
specific situation and how we may contribute to your improved competitiveness and profitability using proven lean manufacturing tools.

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