6 big losses in autonomous maintenance pdf

Cayman systems usa 5 7773394 1998 revision a 980810. 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. Pepatah ini nampaknya sangat relevan bagi production team saat tungganglanggang menghadapi banyaknya breakdown mesin, lambatnya operasi dan kualitas produk yang tidak memuaskan. Tpm basics such as the six big losses, overall equipment effectiveness oee, causes of losses, and six major tpm activities. Education collaboration of production and maintenance maintenance production. Operators are obliged to maintain normal working condition of machines and devices as well as to restore the initial condition of their functioning. Equipment failure a more generalized way to think of equipment failure is as any unplanned stop or downtime. Rollout of plant maintenance planroles of maintenance and engineering personnel roles of technicians and operators keys to success in total productive maintenance.

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. Before discussing about oee, let me remind you of some basic principles of tpm. 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. Fokus utama total productive maintanance atau tpm ini adalah untuk memastikan semua perlengkapan dan. Just like oee, the six big losses have their roots in tpm total productive maintenance. The six big losses are extremely important because they are nearly universal in. Autonomous maintenance put simply is the restoration and prevention of accelerated deterioration and has a major positive effect on oee. An introduction to total productive maintenance tpm. How to calculate overall equipment effectiveness oee this is a primaryimportance topic in the total productive maintenance tpm discipline. 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. It is a step by step improvement process, rather than production teams taking on maintenance tasks.

Setup and adjustment is one of the six big losses of. Capture the six big losses to gain additional actionable insight to the oee factors of availability, performance, and quality. What is tpm total productive maintenance productivity. Planned maintenance through the evaluation of the equipment, initial survey and tagging exercise, return equipment to an. Tpm was created originally by nakajima over 20 years ago, and still considered today the leading plant. The 6 big losses who makes tpm activities happen autonomous maintenance planning for implementationwhat is autonomous maintenance. The six big losses were developed along with the total productive maintenance.

Table 5 the six big losses these losses are typically addressed through the implementation of an oee overall equipment efficiency programme. 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. An introduction to total productive maintenance tpm j. Following are the six big losses which occurs during the production process which are as follows, 1. Section name autonomous maintenance standards inspection section number k created on 050400 page number standard operating procedures task. Autonomous maintenance involves training production operators to enable to take on basic maintenance tasks, freeing maintenance to concentrate on more. A study of total productive maintenance implementation. Root cause analysis of the major equipment breakdown. 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 south african institution of mechanical engineering. One of the most effective paths to improving oee is through the six big losses. These losses can be split into three main categories. Equipment maintenance can be defined as preventing machines from breaking down by selecting what pm analysis basics. To keep value flowing, and maximize your sales and margin contribution, you must engage everyone in establishing and maintaining equipment and process reliability.

The six big losses provide an equipmentbased perspective on lost production time. Improvement of overall equipment effectiveness oee through implementation of autonomous maintenance in crankcase line article pdf available in applied mechanics and materials 761. In fact, one of the goals of tpm is to eliminate the six big losses. Why the six big losses are crucial to your preventative maintenance. Dalam konsep total productive maintenance manufacturing, musuh utama yang wajib diberantas oleh production team adalah six big. Pepatah lama mengatakan jika ingin memenangkan peperangan, maka kenalilah musuhmu.

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. Therefore, the autonomous maintenance groups were formed to increase the maintainability of the equipment. Continuously improving manufacturing tpm, lean and six. 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. The six big losses are extremely important because they are nearly. Keywords total productive maintenance, overall equipment e ffectiveness, six big losses, breakdown.

The 6 big losses associated with equipment categories of maintenance and the elimination of the 6 big losses. 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. Pdf overall equipment effectiveness and the six big losses in. Inspect bath pegs for any damage and check that the springs are in position. A case study on total productive maintenance in rolling mill. Centre for professional development contents introduction to 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. An implementation plan for tpm and five countermeasures for achieving zero breakdowns. Six big losses, biang keladi buruknya kinerja produksi. 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.

Address the six big losses improve manufacturing productivity. 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. 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. Autonomous maintenance for operators by jipm autonomous maintenance 26. Pdf overall equipment effectiveness and the six big. 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.

Chapter 6 impact analysis of tpm on pqcdsm indicators 6. Understanding the need for a planned maintenance system 2. Proposed improvement actions are the application of autonomous maintenance, providing training for operators and maintenance technicians and supervising operators in the workplace. Action plans in implementation of total productive maintenance. New fmm institute centre for professional development sbl. Oee depends on three factors, namely, availability, performance and quality which take into account the six big. Failure elimination through preventivepredictive maintenance 5. Losses in 1971 while at the japanese institute of plant maintenance. The route for autonomous maintenance 1 initial cleaning. Planned maintenance start 6 big losses start individual improvement start 6.

The six big losses in lean explained latest quality. Tpm improves equipment effectiveness lean production. The six big losses have their roots in tpm total productive maintenance. Autonomous maintenance am in metallurgical enetrprise executors of autonomous maintenance are the workers of production lines who operate each of the devices. Total productive maintenance employment business scribd. Schedule proactive maintenance and lubrication activities. He characterized maintenance as the responsibility of all employees. An overview of autonomous maintenance features and checklists for step audits to certify team achievement at each am step. It call for the strong design and maintenance interface. The total productive maintenance training course covers the following topics. Performing manual oee calculations helps reinforce the underlying concepts and. Effective maintenance is progressed by initiating activities designed to reduce failures and gradually building the structure of equipment maintenance. Manufacturing losses are categorized into big losses.

Tpm total productive maintenance engages operators to improve equipment. The six big losses originate from the world of total productive maintenance tpm. The six big losses originate from the world of total productive main tenance. Pdf improvement of overall equipment effectiveness oee. Eliminate problem sources and inaccessible areas 3. What is tpm total productive maintenance in the apparel. Six big losses tpm, oee, and improving productivity oee. Finally, operator training and maintenance regimes like tpm have also had proven. This waste is due to operators, maintenance personal, process, tooling problems and nonavailability of components in.

The 16 losses in total productive maintenance industry forum. Appropriate implementation of total productive maintenance tpm offers tremendous potential in improving, not only the equipment efficiency and. Autonomous activities in the production floor who should. Prinsip prisip yang terdapat pada 5s, merupakan prinsip yang mendasari kegiatan. Analysis of total productive maintenance tpm implementation. Examples of common reasons for equipment failure include tooling failure, breakdowns, and unplanned maintenance. 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. As pointed earlier, the main objective behind tpm implementation is to grow your plants and equipments productivity but with only a modest maintenance investment.