ftm - tpm presentation

7/31/2019 FTM - TPM Presentation

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Total Productive Maintenanceand

FTM From Werardt

A presentation by Werardt Systemss P Ltd


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Increases Productivity

Labor productivity, and Break down reduction

Improves Quality by

Reducing the Defects in processes Reducing Defects in products Reducing Customer complaints

Why TPM?


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Reduces Cost

Reduction in man power Maintenance cost reduction Energy Conservation

Delivery

Stock reduction Inventory turnover increase

Safety Environment

Improvement Ideas increase Small Group meetings increase

Why TPM?


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Financial Return on Investment (ROI)

after 2 to 3 years

Break even on initial TPM

project Less than one year

Reduction in absenteeism, aswork place is enriched

Why TPM?


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Zero unplanned Downtime

Zero Defects

Zero failure

Zero variability Reduced Idle time on machines

Zero Accidents

Maximized P.M. Compliance

Thus Maximizing OEE

TPM Goals

FTM puts you on the road to achieve these Goalsin a Simple, Better and Faster way !


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The Pillars of TPM

TPM is a cultural change and FTMsupplements it in Information management

1 Kobetsu Kaizen - Individual Improvements

2 Jishu-Hozen - Autonomous Maintenance

3 Planned Maintenance

4 Quality Maintenance5 Education and Training

6 Safety and Environment

7 Office TPM

8 Development Management


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Some Facts about TPM & Maintenance

Maintenance can generally account fora major portion of todaysmanufacturing costs

Hence when it comes to TPM

implementation the Maintenancedepartment generally takes the lead

Generally upto 25% of maintenancecost is wasted or not known

Emergency repair jobs are at least

three times more expensive than thesame repair done a pre-planned basis.

Hence TPM & Maintenance go hand-in-hand


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RCFA - Root Cause Failure Analysis

Making P.M. effective and dynamic

Condition & Time Based Maintenance

Doing Why-Why Analysis and maintaining 6W2H

Improving the Reliability of work

Reducing Idle time on repairs

Condition Monitoring and Inspection

Autonomous Maintenance activities

How to achieve Zero Breakdowns?

FTM is very strong in this area !


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Awareness : Understanding your activities, IdentifyingCritical, Essential and Desirable requirements

Business Process Optimization : What processes do youfollow to achieve your objectives? Who is doing what? Arethey trained for the Job? Are required skills available?

Quantification : How many and which type of Jobs do youdo? To focus on the type of work being done, how much isreactive and how much is proactive?

Benchmarking : FTM helps in devising and defining your Key

measuring parameters or KPIs that help in Improvements

Performance Review : And most importantly devising a postimplementation review mechanism to monitor progress

The FTM Steps to Success


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Facilitating autonomous maintenance or Jishu Hozen, throughActivity based PM, and feedback on machine behavior

Applying Kaizen activities to monitor Improvements

Increasing the ease of operation, make it easy from

information and work point of view Improving skills through need based training programs and

easy availability of history

Improving maintainability through condition monitoring andreliable operations

Improving safety through awareness

Maintenance Prevention Design

Applying FTM feedback !


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Key Result Areas

1. Improving human resources

Operators ability to perform Jishu-Hozen

Maintenance employees ability to perform quality & reliable

maintenance Production engineers ability to execute maintenance free

equipment plan

2. Improving Plant & Machinery

Maximizing Uptime

Increased Plant value

Achieving TPR - Total Plant Reliability


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3. Improving the corporate culture

From authoritarian to participative management

Involving everyone in CIP

4. Reducing losses

Down time losses

Speed losses

Defect lossesFTM directly and indirectly helps you in

achieving the above

Key Result Areas


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Contact Information

Werardt Systemss Pvt Ltd

Pune, India

Phone : 91-20-25285256, 25285257

Website : http://www.werardt.com

email: [email protected]

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