TPM pillars and OEE calculation

(a) TPM

Total Productive Maintenance (developed in Japan by Nippondenso and promoted by Seiichi Nakajima) is a company-wide approach in which all employees, from top management to operators, take part in keeping equipment in the best condition. Its aim is zero breakdowns, zero defects and zero accidents. The operator performs routine cleaning, lubricating and inspection (autonomous maintenance), while the maintenance staff do specialised work.

Main pillars (8 pillars)

1. Autonomous maintenance (Jishu Hozen): operator cleans, inspects, lubricates.
2. Planned maintenance: scheduled and predictive maintenance.
3. Focused improvement (Kobetsu Kaizen): remove losses by small team projects.
4. Quality maintenance: keep equipment conditions that give defect-free product.
5. Early equipment management: new equipment designed for easy maintenance.
6. Training and education.
7. Safety, health and environment.
8. Office TPM: remove waste in administration.

The base is 5S. The six big losses are breakdown, set-up and adjustment, idling and minor stops, reduced speed, process defects and start-up losses.

(b) Overall equipment effectiveness

Planned production time $= 480 - 30 = 450$ min. Operating time $= 450 - 45 = 405$ min.

$$\text{Availability} = \frac{405}{450} = 0.900$$ $$\text{Performance} = \frac{\text{ideal cycle time} \times \text{total units}}{\text{operating time}} = \frac{1 \times 340}{405} = 0.8395$$ $$\text{Quality} = \frac{340 - 12}{340} = 0.9647$$ $$OEE = 0.900 \times 0.8395 \times 0.9647 = 0.7289$$

Answer: Availability 90.0%, performance 84.0%, quality 96.5%, OEE = 72.9%.