Page 106 - TPM A Route to World-Class Performance

The TPM improvmt plan 87

Level I Level 2
1 Combination of sporadic and chronic 1 Chronicbreakdowns
breakdowns
2 Sigrufcant breakdown losses 2 Breakdown losses still significant
3 BM > PM 3 PM=BM
4 No operator asset care 4 Operator asset care implemented
5 Unstable lifespans 5 Parts lifespans estimated
6 Equipment weaknesses not recognized 6 Equipment weaknesses well acknowledged
7 MaintainabiLity improvement applied on
above pints
Level 3 Level 4
1 Tune-based maintenance 1 Condition-based maintenance established
2 PbbBM 2 PMonly
3 Breakdown losses less than 1% 3 Breakdown losses from 0.1 % to zero
4 Autonomous maintenance activities 4 Autonomous maintenance activities stable
well established and refined
5 Parts lifespans lengthened 5 Parts lifespans predicted
6 Designers and engineers involved in 6 Reliable and maintainable design developed
higher-level improvements
~~~
BM Breakdown Maintenance PM Predictive Maintenance
Figure 5.7 OEE assessment: breakdom losses

Level 1 kvel2
1 No contml: minimum involvement by 1 Work procedures organized, e.g. internal
operators and external set-up distinguished
2 Work procedures disorganized: set-up and 2 Set-up and adjustment time still unstable
adjustment time varies widely and randomly 3 Problems to be improved are identified
Level 3 he1 4
1 Internal set-up operations moved into 1 Set-up time less than 10 minutes
external set-up time
2 Adjustment mechanisms identified and 2 Immediate product changeover by
well understood eliminating adjustment
3 Error-umofina introduced

Figure 5.8 OEE assessment: set-up and adjustment losses

The improvement cycle in TPM starts from an appreciation of what the six
big losses are and proceeds through problem solving to the establishment of
best practice routines. Eluninating the root causes of the six losses is tackled
in Step 9 of the TF'M improvement plan.
Finally, Figure 5.13 shows a summary of the loss categories with improve-
ment strategy examples.