Page 68 - TPM A Route to World-Class Performance

The top-down and bottom-up realities of TPM 49

In order to provide a precise and firm structure for the TPM process, WCS
International has developed the nine-step TPM improvement plan, which
has three distinct cycles:
1 The measurement cycle
2 The condition cycle
3 The problem prevention cycle
In order to ensure the quality of implementation for each TPM pilot
application, the TPM team members are taken step by step through the main
elements as shown in Figure 3.19.

Measurement cycle

Equipment history record
The TPM team analyse existing information sources and determine the future
records to be kept with regard to the history of the equipment. This will aid
future problem resolution.
OEE measurement and potential
In parallel with this exercise, the team carry out the initial measurement of
overall equipment effectiveness in order to determine current levels of
performance, the best of the best interim targets and the ultimate world-class
levels.
Assess the six losses
This is a ’first cut’ assessment of the impact of each of the six losses, and is
usually aided by ’fishbone‘ analysis charts and ‘brainstorming’ in order to
prioritize the losses.

Condition cycle

Critical assessment
In order to decide which are the most critical items, the TPM equipment team
list the main sub-assets. Then they independently assess each of the sub-
assets from their perspective and rank them on a scale of 1 (low) to 3 (high),
taking into account criteria such as OEE, maintainability, reliability, impact
on product quality, sensitivity to changeovers, knock-on effect, impact on
throughput velocity, safety, environment and cost. The team should reach a
consensus of ranking and weighting of the most critical items.
Other very useful outputs of the critical assessment are that it:
helps to build teamwork;
helps the team to fully understand the equipment;
provides a checklist for the condition appraisal;
provides a focus for future asset care;
highlights safety-critical items;
highlights weaknesses regarding operability, reliability and maintain-
ability.