Total Productive Maintenance - Chapter 1: Introduction

Vocabulary flashcards reviewing core maintenance concepts, goals, organizational structures, types of maintenance, and Total Productive Maintenance (TPM) principles.

Maintenance

All activities necessary in keeping a system and all its components in working order.

Main Objective of Maintenance

To maintain the capability of the system while controlling the cost.

Components of Maintenance Cost

The cost of maintenance labor and material, combined with the cost of production loss due to an inadequate and ineffective maintenance program.

Profit Formula

$$\text{Profit} = \text{Income} - \text{Expenses}$$

Optimum Total Cost Curve

The minimum point on the total cost curve achieved by balancing the increasing cost of preventive maintenance against the decreasing cost of repair and breakdown.

Primary Goals of Maintenance

Maintaining existing equipment; equipment inspection (cleaning, lubrication); equipment modification (alteration & installation); utility generation, distribution & management; maintaining buildings & grounds; and building modifications & alterations.

Secondary Goals of Maintenance

Plant protection & security, salvage & waste disposal, pollution & noise control, and compliance with regulations such as ADA, EPA, and OSHA.

Planning (Maintenance Management)

The maintenance management function that sets goals, objectives, and procedures; establishes task priorities; estimates required resources; establishes limits and tolerances for deviations; and includes performance measures.

Scheduling (Maintenance Management)

The maintenance management function that involves the actual execution of planned or unplanned activities, sets the sequence of outstanding work orders considering priority and availability, and manages the maintenance backlog.

Maintenance Backlog

The accumulated maintenance work needed. Maintaining an appropriate level of backlog is critical, with a recommended rule of thumb average of 2 to 3 weeks.

Crew Size Formula

$$\text{Crew Size} = \frac{\text{Scheduled Labor - Hours per Week}}{(\text{Backlog}) \times (\text{Hours per Week})}$$

Total Productive Maintenance (TPM)

A program seeking continuous and overall improvement in equipment effectiveness through the active involvement of all employees, combining total quality improvement and employee empowerment, with the operator as the key participant and maintenance in an advisory role.

Operator Responsibilities (TPM)

Housekeeping (workplace organization), equipment cleaning, protection from dirt, lubrication, inspection, and routine adjustments.

Obstacles to Full Equipment Effectiveness

The six major obstacles: equipment failure, setup & adjustments, idling & stoppage, reduced speed, defects, and startup problems.

Corrective Maintenance

Required repair work after equipment failure has occurred. It involves unexpected and unplanned repairs, is the most expensive type of maintenance activity, and usually carries the highest priority.

Preventive Maintenance (PM)

Planned activities (routine inspections, cleaning, lubrication) taken to fix problems before failure occurs, relying on accurate equipment history and performed without causing undue burden on production.

Predictive Maintenance (PDM)

A strategy using statistical tools and diagnostics (vibration analysis, chemical analysis of lubricants, thermography, audio gauges) to predict potential failures and schedule preventive actions.

Centralized Maintenance Department

An organizational structure where maintenance personnel report directly to the maintenance department head and are assigned to tasks across various plant areas as needed.

Decentralized Maintenance Organization

An organizational structure that allows individual areas, units, or departments within a facility to have their own dedicated maintenance department.