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TPM: Planned Maintenance (Keikaku Hozen) (PowerPoint PPTX Slide Deck)
PowerPoint (PPTX) 102 Slides
BENEFITS OF THIS POWERPOINT DOCUMENT
- Provides a framework for minimizing the downtime and costs associated with machine breakdowns.
- Provides step-by-step guidance on the implementation of the Planned Maintenance pillar.
- Clarifies the roles of the operations and maintenance departments in supporting the TPM initiative.
TPM PPT DESCRIPTION
Planned Maintenance (Keikaku Hozen) is a proactive approach to maintenance that focuses on minimizing the downtime and costs associated with machine breakdowns. As one of the key pillars of the TPM Excellence framework, the goal of Planned Maintenance is to have trouble-free equipment that produce defect-free products.
Planned Maintenance achieves and sustains availability of machines at an optimum maintenance cost, reduces spares inventory, and improves reliability and maintainability of machines.
In this Planned Maintenance PPT training presentation developed by our JIPM-certified TPM Instructor, you will learn how to plan and organize the Plan Maintenance activities to strengthen the capabilities of your maintenance department under the TPM framework. It includes the four phases to zero breakdowns and step-by-step guidance on the implementation of the Planned Maintenance pillar.
The presentation delves into the critical differences between autonomous and planned maintenance, emphasizing their unique roles in preventing equipment failures. It also outlines the seven steps to implementing a robust planned maintenance system, ensuring long-term operational efficiency.
LEARNING OBJECTIVES
1. Understand what is Planned Maintenance and why it is important in TPM implementation.
2. Acquire knowledge on how to plan and organize Planned Maintenance activities.
3. Describe the seven implementation steps of Planned Maintenance.
4. Gain knowledge on the JIPM TPM Excellence Criteria for Planned Maintenance.
CONTENTS
1. Introduction to Planned Maintenance
• The Vicious Cycle Of Poor Equipment Reliability
• From PM To TPM
• Productive Maintenance ("Profitable PM")
• Preventive Maintenance Is Health Management For Machines
• What Is TPM?
• TPM Is A Paradigm Shift
• Planned Maintenance Is One Of The Foundational Pillars Of TPM
• The 4 Key Pillars That Are Critical For Equipment Reliability
• Difference Between Reliability & Availability
• Difference Between Failure & Breakdown
• TPM – 3 Principles Of Prevention
2. What is Planned Maintenance?
• What Is Planned Maintenance?
• The Basic Idea Of Planned Maintenance: Fix It Before It Breaks
• Dual Focus Of Planned Maintenance
• Difference Between Planned & Preventive Maintenance
• Difference Between Autonomous Maintenance & Planned Maintenance
• Objective Of Planned Maintenance
• Benefits Of Planned Maintenance
• Policy Of Planned Maintenance
• Targets Of Planned Maintenance
• Planned Maintenance – Two Main Activities
• Scheduled Maintenance
• Planned Maintenance Provides A System To Achieve The Natural Life Cycle Of Individual Equipment Elements
3. Planning & Organizing for Planned Maintenance
• Maintenance Planning
• Elements Of A General Maintenance Plan
• TPM Implementation Organization Structure With Planned Maintenance Pillar
• Maintenance Department Organization – Example
• Planned Maintenance Activities
• Tasks For Planned Maintenance
• Planned Maintenance Responsibilities
• Key Roles Of Operations & Maintenance Departments
• Roles Of The Operations Department
• Roles Of The Maintenance Department
• Types Of Maintenance Activities
• Support For Autonomous Maintenance Steps 1-3
• Key Points For Applying Visual Control
• Maintenance & Control
• Lubrication Standards
• Collecting & Using Maintenance-related Information
• MP Design
• The 4 Phases To Zero Breakdowns
• Zero Failure Activities
4. The 7 Steps of Planned Maintenance
• Step 1 – Provide Support & Guidance To Autonomous Maintenance Activities
• Step 2 – Evaluate Equipment & Understand Current Condition
• Step 3 – Restore Deterioration & Correct Weaknesses
• Step 4 – Build An Information Management System
• Step 5 – Build A Periodic Maintenance System
• Step 6 – Build A Predictive Maintenance System
• Step 7 – Evaluate The Planned Maintenance System
5. JIPM TPM Excellence Criteria for Planned Maintenance
• JIPM TPM Excellence Criteria for Planned Maintenance
• How To Sustain TPM & Planned Maintenance Activities
• Critical Success Factors
*Note: The Japan Institute of Plant Maintenance (JIPM) is a nonprofit research, consulting, and educational organization that helps companies increase organizational efficiency and profitability through improved maintenance of manufacturing equipment, processes, and facilities. The JIPM is the sponsoring organization for the TPM Excellence Award, awarded annually to recognize excellence in company-wide maintenance systems. Based in Japan, JIPM is the innovator of methodologies that have been implemented around the world.
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MARCUS OVERVIEW
This synopsis was written by Marcus [?] based on the analysis of the full 102-slide presentation.
Executive Summary
The "TPM: Planned Maintenance (Keikaku Hozen)" presentation is an essential resource for organizations aiming to enhance their Total Productive Maintenance (TPM) practices. Created by a JIPM-certified TPM Instructor with experience at industry leaders, this presentation provides a structured approach to implementing Planned Maintenance. It covers critical aspects such as maintenance planning, the 7 implementation steps, and the JIPM TPM Excellence Criteria. By utilizing this presentation, organizations can minimize equipment downtime, improve reliability, and foster a proactive maintenance culture.
Who This Is For and When to Use
• Maintenance Managers overseeing equipment reliability and maintenance strategies
• Operations Managers focused on optimizing production efficiency
• TPM Coordinators responsible for implementing and sustaining TPM initiatives
• Training and Development Teams aiming to enhance maintenance skills among operators
Best-fit moments to use this deck:
• During TPM training sessions for staff at all levels
• When developing or revising maintenance strategies
• In workshops focused on improving equipment reliability
Learning Objectives
• Understand what Planned Maintenance is and its significance in TPM implementation
• Describe the 7 implementation steps of Planned Maintenance
• Acquire knowledge on how to plan and organize Planned Maintenance activities
• Gain insight into the JIPM TPM Excellence Criteria for Planned Maintenance
Table of Contents
• Introduction to Planned Maintenance (page 1)
• What is Planned Maintenance? (page 2)
• Planning & Organizing for Planned Maintenance (page 3)
• The 7 Steps of Planned Maintenance (page 4)
• JIPM TPM Excellence Criteria for Planned Maintenance (page 5)
Primary Topics Covered
• Planned Maintenance Definition - A proactive maintenance strategy aimed at minimizing downtime and associated costs from equipment breakdowns.
• Importance of Planned Maintenance - Ensures trouble-free equipment operation, defect-free products, and optimal maintenance costs.
• Seven Implementation Steps - A structured approach to implementing Planned Maintenance effectively.
• JIPM Excellence Criteria - Standards that guide organizations in achieving excellence in Planned Maintenance practices.
• Differences Between Maintenance Types - Clarifies distinctions between Planned Maintenance, Preventive Maintenance, and Autonomous Maintenance.
• Maintenance Planning - Outlines the essential elements of an effective maintenance plan, including policies and workflows.
Deliverables, Templates, and Tools
• Maintenance vision and mission statement template
• Standard operating procedures for maintenance tasks
• Maintenance schedule and staffing plan
• Spare parts management system
• Information management system for tracking maintenance activities
• Training materials for developing maintenance skills
Slide Highlights
• Overview of the Vicious Cycle of Poor Equipment Reliability
• Comparison of Planned Maintenance vs. Preventive Maintenance
• Visual representation of the Seven Steps of Planned Maintenance
• JIPM TPM Excellence Criteria checklist for Planned Maintenance
Potential Workshop Agenda
Introduction to Planned Maintenance (30 minutes)
• Overview of Planned Maintenance concepts
• Discussion on the importance of proactive maintenance
Implementation Steps Workshop (60 minutes)
• Review the 7 steps of Planned Maintenance
• Group activity to develop a maintenance plan
Excellence Criteria Review (30 minutes)
• Discuss the JIPM TPM Excellence Criteria
• Identify areas for improvement in current practices
Customization Guidance
• Tailor the maintenance vision and mission statements to align with organizational goals.
• Adjust the maintenance schedule based on specific operational needs and equipment types.
• Incorporate company-specific data into the information management system for better tracking.
Secondary Topics Covered
• The role of operators in Autonomous Maintenance
• Techniques for effective maintenance planning and organization
• Strategies for improving equipment reliability and maintainability
FAQ
What is the main goal of Planned Maintenance?
The primary goal of Planned Maintenance is to ensure trouble-free equipment operation while minimizing downtime and maintenance costs.
How does Planned Maintenance differ from Preventive Maintenance?
Planned Maintenance encompasses any strategy where maintenance tasks are scheduled before faults occur, while Preventive Maintenance specifically refers to scheduled tasks performed to prevent unexpected failures.
What are the 7 steps of Planned Maintenance?
The 7 steps include providing support to Autonomous Maintenance, evaluating equipment condition, restoring deterioration, building an information management system, establishing a periodic maintenance system, developing a predictive maintenance system, and evaluating the Planned Maintenance system.
How can organizations measure the effectiveness of their Planned Maintenance?
Organizations can measure effectiveness through metrics such as Mean Time Between Failures (MTBF) and Mean Time To Repair (MTTR), as well as tracking maintenance costs and equipment availability.
What is the significance of the JIPM TPM Excellence Criteria?
The JIPM TPM Excellence Criteria provide a framework for organizations to achieve high standards in maintenance practices, ensuring continuous improvement and operational excellence.
Glossary
• Planned Maintenance - A proactive maintenance strategy to minimize downtime.
• Preventive Maintenance - Scheduled maintenance tasks performed to prevent equipment failures.
• Autonomous Maintenance - Maintenance activities performed by operators to ensure equipment reliability.
• MTBF (Mean Time Between Failures) - A measure of reliability for repairable items.
• MTTR (Mean Time To Repair) - The time taken to repair a system after a failure.
• JIPM - Japan Institute of Plant Maintenance, an organization that promotes TPM practices.
• TPM - Total Productive Maintenance, a holistic approach to maintenance that involves all employees.
• Condition-Based Maintenance (CBM) - Maintenance performed based on the actual condition of the equipment.
• Time-Based Maintenance (TBM) - Maintenance performed at scheduled intervals.
• Maintenance Prevention - Designing equipment to minimize maintenance needs.
• Failure Analysis - The process of analyzing failures to identify root causes.
• Kaizen - Continuous improvement practices involving all employees.
• Equipment Reliability - The ability of equipment to perform its intended function without failure.
Source: Best Practices in TPM, Planned Maintenance PowerPoint Slides: TPM: Planned Maintenance (Keikaku Hozen) PowerPoint (PPTX) Presentation Slide Deck, Operational Excellence Consulting
ABOUT THE AUTHOR
Operational Excellence Consulting, founded in 2009 by Allan Ung, draws from extensive experience at Microsoft, IBM, and Underwriters Laboratories (UL). We specialize in strategy deployment, customer experience design, and operational excellence, applying Design Thinking, Lean, and Systems Thinking to maximize customer value and minimize waste.
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