16 types of losses in tpm pdf

Before discussing about oee, let me remind you of some basic principles of tpm. In tpm level 1, we aim to create a strong production floor that can generate a high level of profits by reducing production cost see figure 12. One of the main targets with tpm and oee program is to reduce andor eliminate what is called the six big losses the most common reasons to productivity losses within manufacturing. These losses are due to reduction in speed of the equipment. How to improve business competitiveness through kobetsu.

A free powerpoint ppt presentation displayed as a flash slide show on id. Creating a comfortable and employeefriendly workplace by tpm. Of these, losses 9 through are the human losses under tpm. Tpm total productive maintenance is a holistic approach to equipment maintenance that strives to achieve perfect production. Root cause analysis of the major equipment breakdown problems. Total productive maintenance tpm is a system of maintaining and improving the integrity of production, safety and quality systems through the machines, equipment, processes, and employees that add business value to an organization tpm focuses on keeping all equipment in top working condition to avoid breakdowns and delays in manufacturing processes. May 06, 2018 this means that, as explained in table tpm a conceptual guide, in addition to eliminating the 16 big losses relating to equipment, resource consumption and human labour, they must also generate profits by strengthening and improving collaboration among all of the departments concerned with any of the processes involved in planning.

Since 1971 auditing and presenting awards for tpm achievement since 1991 internationally. This type of losses is occurs due to the failure of parts, which causes stop of production. Rootcauses are clear settings documented by package machine type. Many of the tools such as employee empowerment, benchmarking, documentation, etc. It can be considered as the medical science of machines. Being aware of the 6 big losses, enables employees to spot them and either eliminate or minimise them.

The tpm program closely resembles the popular total quality management tqm program. Kobetsu kaizen losses analysis to enhance the overall. Consumable loss effective energy number, weight number of good products weight of good products trimming attrition overweight giveaway 14. Six big losses tpm, oee, and improving productivity oee. Pdf total productive maintenance tpm implementation practice. Jun 02, 2014 8 availability lossesbreakdown loss failure losseslosses due to failures. The goal of this study was to find out the scenario of multiwork loss and operating motion loss in quantitatively in terms of loss. Losses that are accompanied by temporary functional stoppage losses allowing functional recovery through simple measures removal of abnormal work pieces and resetting losses that do not require parts exchange or repair losses that require from 35 seconds to less than 5 minutes for recovery. Tpm improves equipment effectiveness lean production. Tpmcreating standards and preparation for autonomous maintenance 85. This means that, as explained in table tpm a conceptual guide, in addition to eliminating the 16 big losses relating to equipment, resource consumption and human labour, they must also generate profits by strengthening and improving collaboration among all of the departments concerned with any of the processes involved in planning. In any case, see for yourself if any of the list below suits you, it mostly does not for me.

Tpm means equipment is well maintained, eliminating any chance of failures. This waste is due to operators, maintenance personal, process, tooling problems and nonavailability of components in time etc. Overall equipment effectiveness measurement byweighted. Mar 08, 2015 some are from six sigma, others from tpm total productive maintenance, which has 16. Availability takes into account availability loss, which includes all events that stop planned production for an appreciable length of time typically several minutes or longer. These losses are due to the defective product produced during the production process and therefore rework has to be done to remove the defects. This presentation on 16 big losses has been prepared by c.

The 16 losses in total productive maintenance industry forum. Revised settings with notes on quality and accuracy impact. Tpm is now well accepted by the japanese industrial sector. Minor stoppage occurs due to jamming, machine idling. Total productive maintenance tpm is a maintenance program which involves a newly defined concept for maintaining plants and. A case study on total productive maintenance in rolling mill.

Ope, a plant performance evaluation or measurement tool, is introduced by analysis of 16 types of kobetsu kaizen losses. Rev 108 aug 2007 field upgrade should not affect shielded locations. Currently, all tpms must be provisioned to use for txt. Vishwanathan with reference to original literature from tpm total productive maintenance. In this prerecorded, live training seminar shot at the peterbilt manufacturing training center in denton, tx, mike wroblewski, a senior lean consultant from gemba consulting and the kaizen institute explains why total productive maintenance tpm is not optional for lean thinking companies who rely on machines and equipment to satisfy customer demand. In the table below the six big losses are listed and youll see how they are connected and related to factors in the oee calculation. Manufacturing industries are subject to different types of losses and tpm emanates from the need to overcome these losses and integrate maintenance with manufacturing to improve productivity.

First, the manufacturing losses must be identified for various losses in the manufacturing systems. Kobetsu kaizen losses analysis to enhance the overall plant. Changed some physical presence terms to agree with part 2. Office tpm structure office tpm should be started after activating four other pillars of tpm jh, kk, qm, and pm. Seiichi nakajima developed tpm and the six big losses in 1971 while at the japanese institute of plant maintenance. Kobetsu kaizen or the focused improvement pillar of tpm addresses both these types of losses with the activities that maximize the overall effectiveness of equipment, process and plant through uncompromising elimination of 16 types of losses and improvement of performance. To start implementation of tpm firstly top management need to understand that tpm needs to be part of a long term culture change programme, not just an initiative for the maintenance department. The six big losses originate from the world of total productive maintenance tpm. A 7 major losses that can impede equipment efficiency. Good maintenance can be ensured by incorporating the philosophy and principles of total productive maintenance tpm in organizational practices.

By implementing tpm, companies may use it as a panacea for their continual improvement. In this study it is concluded and emphasized that the whywhy analysis and kaizen perform by the plant reduce kobetsu kaizen losses and increase the trend. An introduction to total productive maintenance tpm. Determination of costs resulting from manufacturing losses. Extensive, researchbacked profiles of 16 personality types. Capture the six big losses to gain additional actionable insight to the oee factors of availability. Availability losses 5 1 break down loss failure losses. Action plans in implementation of total productive maintenance. As one of the pillars of tpm activities, kaizen pursues efficient equipment, operator and material and energy utilization, that is extremes of productivity and aims at achieving substantial effects. The total productive maintenance tpm powerpoint also comes with a 19 page workbook. This will benefit the extension of working life of a machine, ease regular smooth handling and functioning, reduceeliminate a number of equipment bound losses and enhance operators. The 6 big losses are the major causes of shortfall in manufacturing and as such are central to overall equipment effectiveness oee. Ppt tpm powerpoint presentation free to download id.

You dont have this metric, so its a good metric to start so everybody understands what the process is of where our losses are coming from and what can we do about it. In the table below the six big losses are listed and youll see how they are connected and related to factors. It blurs the distinction between the roles of production and. Overall plant effectiveness ope, a plant performance evaluation or measurement tool, is introduced by analysis of 16 types of kobetsu kaizen losses.

There are 16 major losses that can impede improvement of. The tpm club india, cii acknowledges the contribution of all the following 41 companies who added great value in sharing their experience of tpm implementation. This waste is due to operators, maintenance personal, process, tooling problems and nonavailability of components in. Tpm emphasizes proactive and preventative maintenance to maximize the operational efficiency of equipment. Tpm aims at maximization of machine utilization and not merely machine availability maximization.

The seven types of waste muda now with 24 more types of. Measurement of tpm losses due to skill level difference of. Tpmanalyzing and categorizing the failure data 61 ftags, the machine history log, and minor stops or unrecorded losses categorizing 63 finding out the tpm causes for the ftags to help find the cure 71 pareto charts 80 the defect map 83 chapter 4. By using minitab 16 software an experimentation has been done on three.

Definition of tpm total productive maintenance is an innovative approach to equipment maintenance involving maintenance personnel and operators working in teams focusing on eliminating equipment breakdowns and equipment related defects. Overall equipment effectiveness oee and the 6 big losses. Type of failure include sporadic function stopping failures and function reduction failure in which the function of the equipment drop below normal levels like replacement of parts and repair, cases requiring 5 minute or more for repair. Management losses from tpm perspective management losses are waiting losses, such as awaiting material, awaiting dolly, awaiting tools, awaiting instructions, and awaiting repair, which are generated through management problems. One of the major goals of tpm and oee programs is to reduce andor eliminate what are called the six big losses the most common causes of equipmentbased productivity loss in manufacturing. These are the losses that impede human work efficiency, thus adversely affecting the productivity of the organization. Tpm level 1 is positioned as a programme for generating profits by eliminating and preventing the constraints and losses that stand in the way of reducing production cost. Focused improvement activity is a priority in the tpm development programme with activities performed by crossfunctional.

Types of failures include sporadic function stopping failures and functionreduction. Waiting losses that are caused by management, such as waiting for material, waiting for a dolly, waiting for tools, waiting for instructions, waiting for repairs of breakdowns, etc. The equipment breaks down causing the function of the line or process to stop. Production losses and overall equipment effectiveness. Excess motion like walking, bending, stretching etc. Target quality for ppm elimination of losses and wastes. Total productive maintenance tpm is a methodology whose aim is to increase the availability investment is reduced as in 4. Kaizen blog 16 types of loss in gemba kaizen institute india. You dont have this metric, so its a good metric to start so everybody understands what the process is of where our losses.

Oee is a metric used for evaluating the success of tpm. These losses can be split into three main categories. At least one company i know generated this due to their hierarchy structure. Equipment failure, setup and adjustments, idling and minor stops, reduced speed, process defects, and reduced yield. Examples include unplanned stops such as breakdowns and other down events and planned stops such as changeovers.

Stoppage losses caused by changing the cutting blade due to breakage or caused by changing the cutting blade when the service life of the grinding stone, cutteror bites has been reached. Types of maintenance, six big losses, tpm pillar, implementations steps, benefits of tpm, case study. A framework for assessing management losses from tpm perspective. Audits are a stepwise process with a progression of awards levels 5 in. As one of the pillars of tpm activities, kaizen activities try to thoroughly eliminate 16 major losses 2. This manual is the third in the sequence of others to come, covering kobetsu kaizen, and office tpm in this year 1 aditya cement 21 lucas tvs. This is a sample of the total productive maintenance training course powerpoint download. Breakdown loss failure losses losses due to failures. In this experiment, the aim is to find the losses of water flow in a pipe system. Tpm awareness information 16 courtesy, in part, of motorola sps. Oee takes into account the six big losses of equipment and indicates.

Type of failure include sporadic function stopping failures and. He characterized maintenance as the responsibility of all employees. Jmac presentation at maintenance resilience asia on oct. Rev 109 oct 2007 cleaned up optin physical presence wording. Download ge6757 total quality management tqm books lecture notes syllabus part a 2 marks with answers ge6757 total quality management tqm important part b 16 marks questions, pdf books, question bank with answers key, ge6757. First the major losses which is caused by the the frictional effect. Kaizen activities try to thoroughly eliminate 16 major losses. Kaizen blog productivity improvement through total.

Study guide introduction to total productive maintenance april 2006 tpm100sg00100. The results of implementation of total productive maintenance tpm program increased plant efficiency and productivity significantly by means of eliminating the major losses. Office tpm must be followed to improve productivity, efficiency in the administrative functions and identify and eliminate losses. Loss structure during production activities 16 majorlosses operating manhours net operational manhours effective man hours valued man hours man hours for turnout loading manhours working hour operating time net operating time valued operating time loading time 9. Target is zero failuresto attain zero failure, it is. Cayman systems usa 5 7773394 1998 revision a 980810 tpm awareness information 2. An introduction to total productive maintenance tpm j. The four kinds of management losses existing in the concerned study area were. It holds computergenerated encryption keys used to bind and authenticate input and output data passing through a system. For calculation of oee, a part of breakdown, which has resulted in loss of opportunity of production, shall be considered. This includes analyzing processes and procedures towards. How to calculate overall equipment effectiveness oee this is a primaryimportance topic in the total productive maintenance tpm discipline. Total productive maintenance overview the mission of each pillar is to reduce loss with the ultimate aim of elimination of all losses. Loss of time wherein machine has stopped on its own, machine has been stopped e.