6 big losses in autonomous maintenance pdf

What is tpm total productive maintenance productivity. Autonomous maintenance involves training production operators to enable to take on basic maintenance tasks, freeing maintenance to concentrate on more. Fokus utama total productive maintanance atau tpm ini adalah untuk memastikan semua perlengkapan dan. Tpm basics such as the six big losses, overall equipment effectiveness oee, causes of losses, and six major tpm activities. Eliminate problem sources and inaccessible areas 3. Manufacturing losses are categorized into big losses. Appropriate implementation of total productive maintenance tpm offers tremendous potential in improving, not only the equipment efficiency and. Tpm improves equipment effectiveness lean production. Six big losses, biang keladi buruknya kinerja produksi.

Autonomous maintenance put simply is the restoration and prevention of accelerated deterioration and has a major positive effect on oee. The six big losses have their roots in tpm total productive maintenance. Pengertian total productive maintenance tpm total productive maintenance atau disingkat dengan tpm adalah suatu sistem yang digunakan untuk memelihara dan meningkatkan kualitas produksi melalui perawatan perlengkapan dan peralatan kerja seperti mesin, equipment dan alatalat kerja. Keywords total productive maintenance, overall equipment e ffectiveness, six big losses, breakdown. The 16 losses in total productive maintenance industry forum. What is tpm total productive maintenance in the apparel. Seiichi nakajima developed tpm and the six big losses in 1971 while at the japanese institute of plant maintenance. Therefore, the autonomous maintenance groups were formed to increase the maintainability of the equipment. An implementation plan for tpm and five countermeasures for achieving zero breakdowns. New fmm institute centre for professional development sbl. Chapter 6 impact analysis of tpm on pqcdsm indicators 6. An overview of autonomous maintenance features and checklists for step audits to certify team achievement at each am step. Oee loss categories availability loss, performance loss, and quality loss can be further broken down into what is commonly referred to as the six big losses the most common causes of lost productivity in manufacturing.

Secondly, the selected plant was put under observation to track oee of the overall plant so that the massive losses could be identified and eliminated throughout the organization and office areas. Failure elimination through preventivepredictive maintenance 5. Education collaboration of production and maintenance maintenance production. Before discussing about oee, let me remind you of some basic principles of tpm. Understanding the basic concepts of tpm the 8 key pillars introduction to am introduction to the 6 big losses and how to address their root causes losses in production process and oee.

Centre for professional development contents introduction to maintenance. Autonomous maintenance atau pemeliharaan mandiri merupakan suatu kegiatan untuk dapat meningkatakan produktivitas dan efesiensi masinperalatan melalaui kegiatan kegiatan yang dilaksanakan oleh operator untuk memelihara mesinperalatan yang mereka tangani sendiri. Pepatah lama mengatakan jika ingin memenangkan peperangan, maka kenalilah musuhmu. Capture the six big losses to gain additional actionable insight to the oee factors of availability, performance, and quality. Autonomous maintenance am in metallurgical enetrprise executors of autonomous maintenance are the workers of production lines who operate each of the devices. Schedule proactive maintenance and lubrication activities. Examples of common reasons for equipment failure include tooling failure, breakdowns, and unplanned maintenance. One of the most effective paths to improving oee is through the six big losses. The six big losses of oee are equipment breakdowns, setup and adjustments, idling and minor stoppages, reduced speed, defects in the process and reduced yieldstartup losses as in 11. The six big losses are extremely important because they are nearly. An introduction to total productive maintenance tpm. This waste is due to operators, maintenance personal, process, tooling problems and nonavailability of components in.

Planned maintenance through the evaluation of the equipment, initial survey and tagging exercise, return equipment to an. Pdf overall equipment effectiveness and the six big losses in. Operators are obliged to maintain normal working condition of machines and devices as well as to restore the initial condition of their functioning. Cayman systems usa 5 7773394 1998 revision a 980810. Action plans in implementation of total productive maintenance. Planned maintenance start 6 big losses start individual improvement start 6. Analysis of total productive maintenance tpm implementation. Improvement of overall equipment effectiveness oee through implementation of autonomous maintenance in crankcase line article pdf available in applied mechanics and materials 761. It call for the strong design and maintenance interface. Dalam konsep total productive maintenance manufacturing, musuh utama yang wajib diberantas oleh production team adalah six big.

Pepatah ini nampaknya sangat relevan bagi production team saat tungganglanggang menghadapi banyaknya breakdown mesin, lambatnya operasi dan kualitas produk yang tidak memuaskan. In fact, one of the goals of tpm is to eliminate the six big losses. 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. 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. Why the six big losses are crucial to your preventative maintenance. Oee depends on three factors, namely, availability, performance and quality which take into account the six big. The total productive maintenance training course covers the following topics. The biggest factor that influences the low value of oee is performance rate with percentage factor six big losses at reduced speed losses of 17. Losses in 1971 while at the japanese institute of plant maintenance. A case study on total productive maintenance in rolling mill. Root cause analysis of the major equipment breakdown.

It is a step by step improvement process, rather than production teams taking on maintenance tasks. Equipment failure a more generalized way to think of equipment failure is as any unplanned stop or downtime. Continuously improving manufacturing tpm, lean and six. The six big losses provide an equipmentbased perspective on lost production time. Prinsip prisip yang terdapat pada 5s, merupakan prinsip yang mendasari kegiatan.

Effective maintenance is progressed by initiating activities designed to reduce failures and gradually building the structure of equipment maintenance. The six big losses were developed along with the total productive maintenance. 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. The south african institution of mechanical engineering. How to calculate overall equipment effectiveness oee this is a primaryimportance topic in the total productive maintenance tpm discipline. Breakdown losses setup and adjustment losses including preventive maintenance idling and minor stoppage losses reduced speed losses quality losses defects rework nonproduction activity startup losses. Tpm was created originally by nakajima over 20 years ago, and still considered today the leading plant. Understanding the need for a planned maintenance system 2. Tpm total productive maintenance engages operators to improve equipment. These losses can be split into three main categories. Total productive maintenance employment business scribd. The six big losses in lean explained in the light of tpm total productive maintenance and oee overall equipment effectiveness program one of the key objectives is to decrease or get rid of what is known as the six big losses that indicates the most common causes in productivity failures within manufacturing. The 6 big losses associated with equipment categories of maintenance and the elimination of the 6 big losses. Performing manual oee calculations helps reinforce the underlying concepts and.

To keep value flowing, and maximize your sales and margin contribution, you must engage everyone in establishing and maintaining equipment and process reliability. Following are the six big losses which occurs during the production process which are as follows, 1. He characterized maintenance as the responsibility of all employees. Inspect bath pegs for any damage and check that the springs are in position. The route for autonomous maintenance 1 initial cleaning. 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 first, lets define the six big losses. The six big losses are extremely important because they are nearly universal in. Six big losses 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 efficiency loss in manufacturing. Finally, operator training and maintenance regimes like tpm have also had proven.

Pdf overall equipment effectiveness and the six big. Just like oee, the six big losses have their roots in tpm total productive maintenance. Proposed improvement actions are the application of autonomous maintenance, providing training for operators and maintenance technicians and supervising operators in the workplace. Pdf on apr 1, 2018, okpala charles chikwendu and others published overall equipment effectiveness and the six big losses in total productive maintenance find, read and cite all the research. Pdf improvement of overall equipment effectiveness oee. A study of total productive maintenance implementation.

The six big losses originate from the world of total productive main tenance. Setup and adjustment is one of the six big losses of. Table 5 the six big losses these losses are typically addressed through the implementation of an oee overall equipment efficiency programme. Address the six big losses improve manufacturing productivity. The six big losses in lean explained latest quality. An introduction to total productive maintenance tpm j. The 6 big losses who makes tpm activities happen autonomous maintenance planning for implementationwhat is autonomous maintenance. The six big losses originate from the world of total productive maintenance tpm. As pointed earlier, the main objective behind tpm implementation is to grow your plants and equipments productivity but with only a modest maintenance investment. Six big losses tpm, oee, and improving productivity oee. Equipment maintenance can be defined as preventing machines from breaking down by selecting what pm analysis basics. Section name autonomous maintenance standards inspection section number k created on 050400 page number standard operating procedures task. Rollout of plant maintenance planroles of maintenance and engineering personnel roles of technicians and operators keys to success in total productive maintenance. Autonomous activities in the production floor who should.