Page 109 - TPM A Route to World-Class Performance

90 TPM-A Route to World-Class Performance

The important components and elements of the process, machine or
equipment are identified: some typical examples are electrics, hydraulics,
pneumatics, cooling systems and control systems. Each of these elements is
assessed in terms of criteria such as the following:

Safety If this component was in poor condition or failed, what would be
the impact on safety due to increased risk of injury?
Availability If this component was in poor condition or failed, what
would be the impact on the availability of the equipment, including set-
up and the need for readjustment of equipment settings?
Performance What impact does this component have on the cycle time or
processing capacity of the equipment when it is available to run?
Quality If this component were in poor condition or failed, what impact
would it have on product quality at start-up and/or during normal
production?
Reliability What impact does the frequency with which this component
fails have on the overall criticality of the equipment?
Maintainability What impact does this component have on the ease of
maintaining or repairing the equipment?
Environment If this component was in poor condition or failed, what
would be the impact on the environment due to emissions, noise, fluid
spills, dust, dirt, etc.?
Cost If this component was in poor condition or failed, what would be
the impact on total cost, including repair and lost production?
Total The sum of the rankings for each component.

The significance of each of the criteria is assessed and allocated a score according
to impact on the process: 1 = no impact, 2 = some impact, 3 = significant
impact.
A typical matrix form for recording process elements and criteria scores is
shown in Figure 5.14. The right-hand (totals) column enables priority to be
applied to those elements most affected. This is further illustrated in Figures
5.15 and 5.16.
The main outputs from the critical assessment process are that it:
starts the teamwork building between operators and maintainers;
results in a fuller understanding of their equipment;
provides a checklist for the condition appraisal;
0 provides a focus for the future asset care;
highlights weaknesses regarding operability, reliability, maintainability.
The critical assessment matrix provides the basis for understanding not just
the most critical components but also those which contribute to special loss
areas. For example, high scores on S, M and R indicate components which
have a high impact on safety, are unreliable and difficult to maintain. A score
of 6 or above on these three is an accident waiting to happen.
Other useful subsets include: