For example, if two components are arranged in parallel, each with reliability R 1 = R 2 = 0.9, that is, F 1 = F 2 = 0.1, the resultant probability of failure is F = 0.1 × 0.1 = 0.01. The resultant reliability is R = 1 – 0.01 = 0.99.

Reliability is calculated as an exponentially decaying probability function which depends on the failure rate. Since failure rate may not remain constant over the operational lifecycle of a component, the average time-based quantities such as MTTF or MTBF can also be used to calculate Reliability.

Reliability describes the ability of a system or component to function under stated conditions for a specified period of time. Reliability is closely related to availability, which is typically described as the ability of a component or system to function at a specified moment or interval of time.

How is MTBF related to FR(N)? MTBF is the reciprocal of FR(N).

Total Productive Maintenance

Total Productive Maintenance (TPM) started as a method of physical asset management focused on maintaining and improving manufacturing machinery, in order to reduce the operating cost to an organization.

How to Implement TPM

1. Announce plans for TPM implementation.
2. Identify an area for a pilot TPM program.
3. Focus on restoring targeted equipment to prime working condition.
4. Begin to measure Overall Equipment Effectiveness (OEE)
5. Address Major Loss Causes.
6. Implement specific TPM concepts as needed.

At its core, TPM is about improving equipment reliability through taking ownership and pride in its upkeep. Done correctly, TPM can have measurable, lasting results such as improved quality output, improved manufacturing maintenance regime, reduced changeover and a proactive culture that “Takes Pride in its Machinery”.

These basic seven pillars are:

• Autonomous maintenance.
• Kobetsu Kaizen (Focused Improvement)
• Planned Maintenance.
• Quality maintenance.
• Training and Education.
• Office TPM.
• Safety Health Environment (SHE)

The last pillar of Total Productive Maintenance is setting standards for the working conditions of all employees by eliminating potential health and safety risks. An example of such an activity includes the implementation of a set of measures (as guards, work standards) making machines safe to use.

OEE (Overall Equipment effectiveness) is the main performance measure that drives action within Total Productive Maintenance (TPM) and is used by the teams to focus their continuous improvement activities as well as identifying those areas that require resource.

In practice, it is calculated as: OEE = Availability × Performance × Quality. If the equations for Availability, Performance, and Quality are substituted in the above equation and then reduced to their simplest terms the result is: OEE = (Good Count × Ideal Cycle Time) / Planned Production Time.

Overall equipment effectiveness

8 Pillars of Activity

• Pillar 1: Autonomous Maintenance.
• Pillar 2: Process & Machine Improvement.
• Pillar 3: Preventative Maintenance.
• Pillar 4: Early Management of New Equipment.
• Pillar 5: Process Quality Management.
• Pillar 6: Administrative Work.
• Pillar 7: Education & Training.
• Pillar 8: Safety & Sustained Success.

Jishu Hozen is a Japanese word that means autonomous maintenance. “Jishu” loosely translated, means – independence, autonomy. Jishu Hozen is one of the eight pillars of Total Productive Maintenance, the other seven being: Focussed Improvement. Planned Maintenance.

Early Management is the fifth pillar of TPM and aims to implement new products and processes with vertical ramp up and minimised development lead time.

There are five core elements to a TPM program:

• Operator Self-Maintenance – Basic program of cleaning, lubrication, general inspection, and minor preventive maintenance to be completed by production operators (associates).
• Conduct Planned Maintenance – Develop and execute planned maintenance activities.

TQM, or total quality management, is a management philosophy based on quality control, whereas total productive maintenance, or TPM, is a concept focused on improving maintenance processes through predictive and preventative maintenance. TQM is focused more on customer needs, expectations, and satisfaction.

Objectives of Maintenance Management

• Control Costs and Budget.
• Comply with Regulations.
• Plan Maintenance Work.
• Ensure Personnel Safety.
• Minimize Equipment Failure and Production Downtime.
• Extend Useful Machine Life.
• Improve Product Quality.
• Develop Improved Policies, Procedures, and Standards.

The study reveals that the TPM Pillar – focused improvement, planned maintenance, autonomous maintenance and Training and education have significant contribution towards manufacturing performance such as lower cost, higher equipment availability, strong delivery and increased Flexibility.

• TPM Pillar 1: Autonomous Maintenance (Jishu Hozen)
• TPM Pillar 2: Planned Maintenance.
• Pillar 3: Quality Maintenance.
• Pillar 4: Focused Improvement (Kobetsu Kaizen)
• Pillar 5: Early Equipment Maintenance.
• Pillar 6: Education and Training.
• Pillar 7: Health, Safety & Environment.
• Pillar 8: TPM in Office Functions.

Total productive maintenance (TPM) is the process of using machines, equipment, employees and supporting processes to maintain and improve the integrity of production and the quality of systems.

TPM is implemented in industry for improving production efficiency with an ultimate aim of attaining zero breakdowns, zero losses and zero defects. KK pillar helps to attain zero losses and to improve Overall Equipment Efficiency(OEE) of the processes and the plant.

16 Industrial Losses

• Breakdown loss.
• Set up & adjustment loss.
• Start-up loss.
• Minor stoppage.
• Defect and rework loss.
• Speed reduction loss.
• Tool change loss.
• Shutdown loss.

4 Types

Overall equipment efficiency (OEE) is a total productive maintenance (TPM) module; machine capacity is a part of all three terms: availability, performance, and quality. Each term present numerous improvement opportunities. Presentation contents: 1. OEE calculation to find the improvement opportunities.

Total Productive Maintenance (TPM) by Operational Excellence Consulting. As a company-wide initiative, Total Productive Maintenance (TPM) maximizes the effectiveness of equipment. TPM brings maintenance into focus as a necessary and vitally important part of the business.

OEE= Availability x Performance x Quality Availability = Operating Time/ Planned 26 Production Time Planned Production Time = Plant Operating Time – Planned Shutdown Plant Operating Time= 8 hours x 60 = 480 min.

OEE = Availability x Performance x Quality. If you substitute in the equations for Availability, Performance and Quality, and then reduce them to their simplest terms, the result is: OEE = Good Pieces x Ideal Cycle Time/Planned Production Time.