Maintenance System Industrial Engineering

News - Information for Maintenance Operation Analysis

https://nraoiekc.blogspot.com/2020/07/news-information-for-maintenance.html

University of Reims Champagne Ardenne
MAINTENANCE AND INDUSTRIAL ENGINEERING (GIM)

UNIVERSITY TECHNOLOGICAL DEGREE IN MAINTENANCE AND INDUSTRIAL ENGINEERING (GIM)
http://www.univ-reims.eu/courses/available-courses/degrees-and-preparations-to-teacher-examinations/science-technologies-health/university-technological-degrees,177,261.html

Maintenance system  industrial engineering is the study of resource use in various maintenance activities with a view to increasing the efficiency or eliminating the waste wherever possible. While the maintenance is carried out to keep the machines and equipment in good condition to perform, resources are used the activity. This resource use is carefully investigated by the industrial engineering to identify and remove waste. Industrial engineering succeeded in reducing the cost of many processes designed in the first iteration by the managers by significant percentage and hence it is a very important activity in systems design or systems engineering.

Famous example of  manufacturing industrial engineering, is Henry Ford's production system redesign, that reduced the price of the automobile by half. Taylor reduced cost of many manufacturing activities. Gilbreth and Harrigton Emerson also achieved similar cost reduction in construction activity and rail road operations.

Industrial engineering has two components - System efficiency engineering and Human effort industrial engineering.

In another explanation, we can say industrial engineering consists of productivity science, productivity engineering and productivity management.


System Industrial Engineering - System Human Effort Engineering - System Efficiency Engineering

Human Effort Engineering - Techniques

1. Principles of Motion Economy
2. Motion Study
3. Workstation Design
4. Application of Ergonomics and Biomechanics
5. Fatigue Studies
6. Productivity/Safety/Comfort Device Design
7. Standardization of  Methods
8. Operator training
9. Incentive Systems
10. Job Evaluation
11. Learning effect capture
12. Work Measurement


EFFICIENCY IMPROVEMENT TECHNIQUES OF INDUSTRIAL ENGINEERING


1. Process Analysis
2. Operation Analysis
3. Layout Efficiency Analysis
4. Value engineering
5. Statistical quality control
6. Statistical inventory control and ABC Classification Based Inventory Systems
7. Six sigma
8. Operations research
9. Variety reduction
10. Standardization
11. Incentive schemes
12. Waste reduction or elimination
13. Activity based management
14. Business process improvement
15. Fatigue analysis and reduction
16. Engineering economy analysis
17. Learning effect capture and continuous improvement (Kaizen, Quality circles and suggestion schemes)
18. Standard costing

Industrial Engineering in Different Functions of an Industrial Organization

Industrial Engineering in Data Center Design and Processes

https://nraoiekc.blogspot.com/2020/07/industrial-engineering-in-data-center.html

Logistics System Industrial Engineering

https://nraoiekc.blogspot.com/2021/06/logistics-system-industrial-engineering.html

Maintenance 

Maintenance System Industrial Engineering

https://nraoiekc.blogspot.com/2012/09/maintenance-system-industrial.html

Product Industrial Engineering

https://nraoiekc.blogspot.com/2012/09/product-design-industrial-engineering.html

Quality - Inspection System Industrial Engineering

https://nraoiekc.blogspot.com/2012/10/quality-system-industrial-engineering.html

Supply Chain Industrial Engineering - Bibliography

https://nraoiekc.blogspot.com/2012/01/supply-chain-industrial-engineering.html

Industrial Engineering Techniques Specially Applied in Maintenance IE

Replacement analysis
Group replacement analysis
Total productive maintenance
Predictive maintenance - IIoT Support
Spare parts inventory decisions
Spare parts storage
Maintenance activities ergonomics
Maintenance work measurement
Lean Maintenance - Lean Smart Maintenance
Poka Yoke design for maintenance
Reduction of maintenance time (using 5S and SMED techniques)

New techniques - 2017

Smart Maintenance
Maintenance 4.0

Advanced predictive maintenance (PdM), enabled by extensive sensor integration and machine-learning techniques, is one of the most widely-heralded benefits of the fourth industrial revolution. The idea is certainly a compelling one, and many companies in asset-intensive sectors are pursuing  investments in digital maintenance and reliability. Many companies are offering summer internships to students in this area and are getting pilot projects done.

Progress of Industrial Engineering of Maintenance in Japan.

1961 The Japan Management Association (JMA) establishes a Plant Maintenance Committee.  JMA is the body responsible for promotion of scientific management in Japan.
1964 A system for awarding PM Awards is established.
1969 The Plant Maintenance Department is dissolved and the Japan Institute of Plant Engineers is established.
1971 The concept of plant maintenance with total participation (Total Productive Maintenance) is proclaimed.
1981 The Japan Institute of Plant Maintenance is launched, following approval from the Ministry of International Trade and Industry as charitable corporation.
1989 The definition of TPM is revised. The Society of Plant Engineers Japan is established.
1990 The Japan Association of Maintenance and Service Contractors is launched.
2005 JIPM Solutions company limited is separated and transferred from JIPM as a profit-seeking corporation.
2012 JIPM was approved as a public interest incorporated association by the prime minister.

https://www.jipm.or.jp/en/company/history/

Mission Statement JIPM 2017

We contribute to promoting safe, secure and reliable production and maintenance activities, as well as stabilizing and improving quality, in the world of industry through supporting problem-solving related to the enhancement of productivity, equipment-management technologies, and maintenance technologies and skills.

https://www.jipm.or.jp/en/company/mission/

Total productive maintenance - Evolution in Industrial Engineering/Scientific Management

In a message in a 2013 JIPM video, Seiichi Nakajima mentions the foundation of industrial engineering in the development of total productivity maintenance. 

https://www.youtube.com/watch?v=sZezLYax8E0

Total productive maintenance is planned maintenance is for increasing productivity and reducing defects. It is a zero defect, zero loss approach to equipment engineering and management involving design, manufacturing, operation, and maintenance.

Digital-Maintenance - McKinsey

To capture everything digital can offer in increasing reliability and reducing costs, companies should boost their digital-maintenance ambitions.

Advanced predictive maintenance (PdM), enabled by extensive sensor integration and machine-learning techniques, is one of the most widely-heralded benefits of the fourth industrial revolution. The idea is certainly a compelling one, and it is encouraging companies in asset-intensive sectors to pursue investments in digital maintenance and reliability.

However, treating PdM as panacea for maintenance and reliability challenges may prove to be short-sighted. Today's advanced predictive techniques can only be practically applied to a subset of use cases. An over-emphasis on one approach means companies won’t position themselves to capture all the potential benefits of a fully digitized maintenance and reliability function. Companies  focused on increased uptime and improved maintenance efficiency have to use all the techniques available.

https://www.mckinsey.com/business-functions/operations/our-insights/digitally-enabled-reliability-beyond-predictive-maintenance

Lean Smart Maintenance (LSM)

Maintenance is a strategic factor and key enabler for smart factories. Therefore, it needs to be intelligent – SMART – and cost-efficient – LEAN. The Lean Smart Maintenance (LSM) concept combines these two perspectives and enables a dynamic, smart and value-oriented maintenance/asset management for smart factories. This paper introduces LSM and explains its major components. It consists of efficiency drivers, e.g. maintenance processes and planning, outsourcing, and effectiveness factors, e.g. data and knowledge management, qualification and maintenance strategy. Besides that, an LSM implementation model is introduced. The four-step LSM implementation model is described with a maintenance strategy example.

http://www.lean-smart-maintenance.net/fileadmin/projects/lsm/Publikationen/LSM_WhitePaper.pdf


Articles and Papers

A PROPOSED MODEL FOR THE DEVELOPMENT AND IMPLEMENTATION OF A MAINTENANCE MANAGEMENT SYSTEM

Published 2025-12-11

Nigel Sookdeo, Dave Persad

https://journals.sta.uwi.edu/ojs/index.php/iemj/article/view/10364

Emerson Process Management on Maintenance Cost Reduction, Time Reduction, Productivity Improvement

Reducing operations & maintenance costs - Emerson

Emerson Process Management 2003.  www.PlantWeb.com. Reducing operations & maintenance costs with PlantWeb® digital plant architecture.

https://www.emerson.com/documents/automation/product-data-sheet-reducing-operations-maintenance-costs-en-41038.pdf

PlantWebís predictive intelligence increases maintenance productivity by detecting and diagnosing potential equipment problems before they grow ñ  reducing the frequency, severity, and cost of repairs while enabling your team to  avoid unnecessary and unproductive tasks.

%RAV. One frequent benchmark of maintenance productivity is annual maintenance cost as a percentage of replacement asset value (RAV). For example, a plant spending $5,000,000 annually to maintain assets that  could be replaced for $100,000,000 has a 5% RAV.

The worst plants are operating with 20% RAV. The best are operating with 2% RAV. Typical plants operate at 6 to 7% RAV.

For a plant with $250,000,000 in assets to maintain, moving from typical to best-in-class status could mean over $10,000,000 in annual savings.

Recent data shows that 86% of maintenance is reactive (too late) or preventive (unnecessary). 

Span of control. For operations, one measure of productivity is the number of loops each operator manages. 

A typical plant might have 125 loops per operator, so managing 1500 loops would require 48 operators to staff four shifts. In a best-in-class plant, on the other hand, each operator might handle 250 loops ñ requiring only 24 operators over the same number of shifts. At a fully burdened cost of $80,000 per year for each operator, the savings would approach $2,000,000 annually. Even greater productivity and economic benefits are possible when operators also have the tools and information to continuously optimize energy use, feedstocks, and other economic factors for the loops they control, as well as to reduce costs in related areas such as safety, health, and environment; utilities; and waste and rework.

Waste in Maintenance Activities

Too much of the work done by maintenance teams is unnecessary, unproductive, or even counterproductive. 

Unnecessary work. Over half of typical maintenance activities are unnecessary. This includes routine equipment checks as well as preventive maintenance on equipment that doesnít need it. 

• One analysis showed that 63% of all instrument work orders did not result in corrective action, because there was nothing wrong with the equipment. 

• A study of 230 valves scheduled for rebuilding during a shutdown found than only 31% needed such extensive service. 

Unproductive work. In a typical plant, the maintenance department averages about 30% is wrench time. The rest of the time they are doing data entry and retrieval, work-order reporting, and other paperwork. Best-practices plants use automated tools to manage this information more efficiently, increasing wrench time to 50% or more.

Counterproductive work. Some maintenance actually reduces equipment reliability. Problems can result from incorrect re-assembly, incorrect tightening, misalignment, or other errors. In fact, as many as 

70% of equipment failures happen shortly after initial installation or major preventive maintenance.

 

Inefficient  maintenance strategies 

 Many of these problems could be reduced by adjusting the mix of reactive, preventive, predictive, and proactive maintenance strategies so maintenance workers can focus on doing the right things at the right time. 

1. Reactive maintenance. Fixing equipment when it breaks. This is the most basic maintenance strategy. Its major drawback is obvious: the cost to repair (or replace) equipment that ís run to failure is typically 

much higher than if the problem were detected and fixed earlier. Also there is additional  cost of lost production during extended downtime. 

2. Preventive maintenance. A preventive strategy assumes equipment is relatively reliable until, after some period of time, it enters a wear-out zone where failures increase. To postpone this wear-out, equipment is serviced on a calendar- or run-time basis. It may or may not require the maintenance. On 

average, preventive maintenance  is about 30% less expensive than reactive maintenance. Hence development of preventive maintenance method gave higher productivity and lower costs.

But about 30% of preventive maintenance effort is wasted, and another 30% turns out to be harmful because of errors committed in disassembly and reassembly and calibration. 

3. Predictive maintenance. The third strategy overcomes these drawbacks by constantly monitoring actual equipment condition and using the information to predict when a problem is likely to occur. With 

that insight, you can schedule maintenance for the equipment that needs it ñ and only what needs it − before the problem affects process or equipment performance. That ís a great way to improve maintenance productivity, as well as reduce costs for repairs and unexpected downtime. 

A best-practices plant uses predictive maintenance for most equipment where condition-monitoring is practical, limiting reactive and preventive strategies to equipment that ís not process-critical and will cause little or no collateral damage if run to failure.

4. Proactive maintenance. The next strategy is proactive maintenance, which analyzes why performance is degrading and then corrects the source of problems. The goal is not just to avoid a hard failure, but to 

restore or even improve equipment performance. For example, a valve failure might be caused by excess packing wear, which in turn was caused by poor loop tuning that caused the valve to cycle continuously. Retuning the loop will prevent further failures while also improving process performance. 

The best-practices plant of the future will actually spend more on maintenance to include this proactive approach in their arsenal ñ and more than regain the investment in increased plant efficiency.

Training Course from Emerson - 2003 - Operations & Maintenance 101 - Maintenance Strategies and Work Practices to Reduce Costs

https://www.emerson.com/documents/automation/training-maintenance-strategies-work-practices-to-reduce-costs-en-41084.pdf

Rosemount 5300 Guided Wave Radar with a Smart Wireless THUM™ Adapter.: Reduce Operations and Maintenance Costs with Guided Wave Radar Diagnostics and Wireless Communication

Potential Results 

• Reduce operations costs

• Decrease maintenance costs

• Minimize risk of lost throughput 

• Decrease safety risks

• Reduce project costs

2010

https://www.emerson.com/documents/automation/case-study-reduce-operations-maintenance-costs-guided-wave-radar-diagnostics-wireless-communication-rosemount-en-87502.pdf

ESSENTIAL ASSET MONITORING.

Improve Reliability and Reduce Your Costs.

Up to 5 percent of production availability is lost annually due to unscheduled slowdowns and shutdowns. 

Just nine asset classes account for the majority of this loss.

2013

https://www.emerson.com/documents/automation/brochure-eam-business-brief-en-41836.pdf

Emerson Provides Services to  Alaska's Largest Wind Farm 

08/09/2021

Emerson announced the completion of a digital transformation project to increase the reliability of clean energy generation at Golden Valley Electric Association’s (GVEA) Eva Creek wind farm. The project improves the management of Alaska’s largest wind farm.

Emerson’s sustainable grid solutions have delivered fast results, increasing the reliability of GVEA’s wind turbines and contributing to a 65% reduction in operations and maintenance costs.

https://www.powersystemsdesign.com/articles/emerson-helps-alaskas-largest-wind-farm-w-affordable-clean-energy/31/18111

More Articles

----------------------------

Lubricants and Productivity

https://nraoiekc.blogspot.com/2019/06/lubricants-and-productivity.html

LUBRICATION AND GREASING: WORKING PRINCIPLE
22 July 2016
https://www.mobility-work.com/blog/lubrication-and-greasing-working-principle

AUTONOMOUS MAINTENANCE: 5 STEPS TO SUCCESSFUL IMPLEMENTATION
4.0 Context
https://www.mobility-work.com/blog/autonomous-maintenance-5-steps-to-successful-implementation
29.5.2016


Why You Should Try Smart Maintenance
http://www.reliableplant.com/Read/30723/smart-maintenance

What Is Lean Maintenance?
2004
http://www.mt-online.com/october2004/what-is-lean-maintenance

Six Sigma Keys to Lean Maintenance
2004
http://www.mt-online.com/november2004/six-sigma-keys-to-lean-maintenance

Six Sigma in Maintenance
SIX SIGMA CONCEPT IN THE MAINTENANCE PROCESS OF TECHNICAL SYSTEMS
2005
http://facta.junis.ni.ac.rs/me/me2005/me2005-08n.pdf

Plant maintenance management practices in automobile industries: A retrospective and literature review
2010
http://upcommons.upc.edu/revistes/bitstream/2099/9948/1/pophaley.pdf


Total Productive Maintenance Review and Overall Equipment Effectiveness Measurement
Osama Taisir R.Almeanazel
Department Of Industrial Engineering, Hashemite University, Zarqa, 13115 Jordan
http://www.jjmie.hu.edu.jo/files/v4n4/JJMIE-129-08_Revised(11)/JJMIE-129-08_modified.pdf



VTT operation and maintenance solutions deliver trouble-free, predictable fleet operation. Our smart solutions optimize safe fleet operation and maintenance, and constitute new competitive service business models for your knowledge-intensive services. Thanks to our significant experience and deep knowledge in this area, we are able to optimize the total operating performance of your fleet. We can also minimize your maintenance time with fast failure identification and recovery.
http://www2.vtt.fi/service/machines_and_vehicles_operation_and_maintenance.jsp?lang=en


Analysis and Scheduling of Maintenance Operations for a Chain of Gas Stations
Mehmet Savsar
Kuwait University, College of Engineering and Petroleum, P.O. Box 5969, 13060 Safat, Kuwait
Journal of Industrial Engineering
Volume 2013 (2013), Article ID 278546
Received 6 November 2012; Revised 2 February 2013; Accepted 3 February 2013
http://www.hindawi.com/journals/jie/2013/278546/


Analysis on Costs for Aircraft Maintenance
U. PeriyarSelvam, T. Tamilselvan, S. Thilakan and M. Shanmugaraja
Department of Aeronautical Engineering, Park College of Technology,
Karumathampatti, Coimbatore – 641 659.
Advances in Aerospace Science and Applications.
ISSN 2277-3223 Volume 3, Number 3 (2013), pp. 177-182
© Research India Publications
http://www.ripublication.com/aasa.htm
http://www.ripublication.com/aasa/aasav3n3spl_08.pdf

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An Assessment of Maintenance Practices and problems in Jordanian Industries
K. K. Tahboub. 2011
Department of Industrial Engineering, Faculty of Engineering and Technology, University of Jordan, Amman, Jordan

http://jjmie.hu.edu.jo/files/v5n4/JJMIE-206-09.pdf


ESTABLISHING MAINTENANCE RESOURCE LEVELS USING SELECTIVE MAINTENANCE
Ilyas Mohammed Iyoob, Department of Mechanical Engineering, The University of Texas at Austin,
Austin, Texas, USA
C. Richard Cassady, Department of Industrial Engineering, University of Arkansas,
Fayetteville, Arkansas, USA
Edward A. Pohl, Department of Industrial Engineering, University of Arkansas, Fayetteville,
Arkansas, USA
2006
http://ilyasiyoob.com/IyoobCassadyPohl_The_Engineering_Economist.pdf


ANALYSIS OF MANAGEMENT METHODS AND APPLICATION
TO MAINTENANCE OF GEOTHERMAL POWER PLANTS
MSc thesis
Department of Mechanical and Industrial Engineering
University of Iceland
2008
http://www.os.is/gogn/unu-gtp-report/UNU-GTP-2008-05.pdf




DUTTA, U, Maze, T, (1987) APPLICATION OF INDUSTRIAL ENGINEERING TECHNIQUE IN TRANSIT MAINTENANCE, ITE Journal, Volume 57, Issue 6, p. 45-49.
http://www.worldtransitresearch.info/research/1757/



Maintenance and Industrial Engineering (GIM)
University Technological Degree in Maintenance and Industrial Engineering (GIM)
http://www.univ-reims.eu/courses/available-courses/degrees-and-preparations-to-teacher-examinations/science-technologies-health/university-technological-degrees,177,261.html


Book Engineering Maintenance - Modern Approach - B.S. Dhillon, 2002
http://site.iugaza.edu.ps/sabdelall/files/2010/02/Engineering_Maintenance_a_modern_approach.pdf




Just-in-time Maintenance, Repair, & Overhaul (Presentation)
Anonymous. IIE Annual Conference. Proceedings (2008): 1-34.



Updated 

 2026 - 1.4.2026

2022 - 8.2.2022,   2021 - 3.12.2021 18 Nov 2021,  4 August 2021, 24 May 2021,  2019 - 24 August 2019

2018 -  12 June 2018, 21 August 2017,  21 April 2015
First published on 27 September 2012

Total Productive Maintenance (TPM) - Bibliography

JMAC TPM pages - guidance tips - pages to be collected

2022

Sundaram Auto Components bestowed with TPM Excellence Award for its Mysuru plant

Mysuru plant one of 25 manufacturing units globally to bag the honour for 2021.

February 2, 2022

Sundaram Auto Components Limited (SACL), a TVS Group Company and one of India’s leading plastic auto component manufacturers, has been recognised in the category, ‘Total Productive Maintenance (TPM) Excellence Award’- presented by Japan Institute of Plant Maintenance (JIPM) for its Mysuru plant.    With this award, SACL joins the elite list of other 24 companies globally and six within India to be conferred this award.

https://www.manufacturingtodayindia.com/sectors/sundaram-auto-components-bestowed-with-tpm-excellence-award-for-its-mysuru-plant

 

2021

https://www.sciencedirect.com/science/article/pii/B9780128194263000059

https://www.4industry.com/overview-of-tpm-manufacturing/

Digital maintenance is discussed in the above article. You can download connected worker use case library - collection of case studies from the article.

https://www.emerald.com/insight/content/doi/10.1108/JQME-09-2020-0098/full/html

https://www.linkedin.com/pulse/maintenance-40-total-productive-tpm-emiro-v%C3%A1squez

https://turcomat.org/index.php/turkbilmat/article/view/3813

http://www.ieomsociety.org/singapore2021/papers/826.pdf

https://asq.org/training/total-productive-maintenance-tpmtqg

https://hal.archives-ouvertes.fr/hal-03384467/document

https://publisher.uthm.edu.my/ojs/index.php/IJSCET/article/view/6293

https://www.researchgate.net/publication/332550822_Application_of_Total_Productive_Maintenance_in_Service_Organization

https://www.scielo.br/j/gp/a/R7x6DPTx5QLgkjJWpXWJhpQ/

https://www.ciiblog.in/benefits-of-planned-maintenance-the-tpm-approach/

https://itegam-jetia.org/journal/index.php/jetia/article/view/740

https://www.egyankosh.ac.in/bitstream/123456789/11700/1/Unit-18.pdf

https://www.jetir.org/view?paper=JETIR1405007

http://ijdri.com/me/wp-content/uploads/2021/05/18.pdf

https://www.taylorfrancis.com/chapters/edit/10.1201/9781315164809-73/total-productive-maintenance-implementation-way-improve-working-conditions-val%C3%A9rio-nunes

https://econpapers.repec.org/RePEc:eee:proeco:v:95:y:2005:i:1:p:71-94

https://curve.coventry.ac.uk/open/items/87f6ff65-bfd6-4b5e-8264-c00976721a8c/1  phd thesis

https://tulip.co/library/suites/total-productive-maintenance-app-suite/

http://repository.sustech.edu/handle/123456789/26702

https://www.ejers.org/index.php/ejers/article/view/2376

https://search.proquest.com/openview/6c52cd3ea14e74ee0b7a04033ff56cfa/1?pq-origsite=gscholar&cbl=2026366&diss=y

https://riunet.upv.es/bitstream/handle/10251/180464/Saxena%20-%20Total%20productive%20maintenance%20TPM%20as%20a%20vital%20function%20in%20manufacturing%20systems.pdf?sequence=1&isAllowed=y

https://kuwaitjournals.org/jer/index.php/JER/article/view/10475

http://ijarsct.co.in/Paper1626.pdf

https://www.academia.edu/56914267/Total_Productive_Maintenance_in_RMG_Sector_A_Case_Burlingtons_Limited_Bangladesh

https://interpro.wisc.edu/courses/improving-equipment-uptime-and-performance-with-tpm/

https://www.tandfonline.com/doi/full/10.1080/01969722.2021.2018549

https://www.hcltech.com/sites/default/files/resources/brochure/files/2021/05/24/hcl_connected_asset_management_brochure.pdf

http://www.repository.rmutt.ac.th/dspace/bitstream/123456789/2846/1/RMUTT-151694.pdf

https://josi.ft.unand.ac.id/index.php/josi/article/view/529

https://www.routledge.com/TPM-Collected-Practices-and-Cases/Press/p/book/9781563273285

https://www.adlittle.com/en/insights/viewpoints/sustainable-and-highly-productive-supply-chain

https://www.frost.com/news/press-releases/abb-recognized-by-frost-sullivan-for-enabling-optimal-process-optimization-and-energy-efficiency-with-its-market-leading-electrification-of-desalination-solutions/

2020

https://www.machinemetrics.com/blog/total-productive-maintenance-iiot

https://scholar.uwindsor.ca/etd/8347/

https://papers.ssrn.com/sol3/papers.cfm?abstract_id=3590948

https://www.jiem.org/index.php/jiem/article/download/3286/957

https://www.plantengineering.com/articles/how-tpm-boosts-productivity-in-manufacturing/

https://www.linkedin.com/pulse/tpm-l%C3%A0-g%C3%AC-total-productive-maintenance-minh-nguy%E1%BB%85n

https://www.researchgate.net/publication/333115252_A_study_of_total_productive_maintenance_TPM_and_lean_manufacturing_tools_and_their_impact_on_manufacturing_performance

http://portal.amelica.org/ameli/jatsRepo/300/3001776015/html/index.html

https://www.ijesi.org/papers/Vol(9)i6/Series-1/E0906012941.pdf

https://www.academia.edu/40806097/Total_Productive_Maintenance_Practices_and_implementation_examples_from_Bottlers_Nepal_Limited

https://www.tetrapak.com/content/dam/tetrapak/publicweb/gb/en/services/documents/case-tps-CIP.pdf

https://www.semanticscholar.org/paper/Total-Productive-Maintenance-Review%3A-A-Case-Study-Singh-Rastogi/f2be9514afeaf108ece0cd44b61612ff0f7b534c

https://www.emerald.com/insight/content/doi/10.1108/JQME-11-2020-0118/full/pdf

https://leanmanufacturing.online/total-productive-maintenance-in-supply-chain-management-part-1/

https://www.tvsts.com/tpm

https://www.ijsr.net/archive/v9i12/SR201122152147.pdf

https://www.ijrar.org/papers/IJRAR2001384.pdf

https://www.ijert.org/tpm-based-focused-breakdown-reduction-strategy-in-industry

http://nopr.niscair.res.in/handle/123456789/55476

http://arcnjournals.org/images/ASPL-IJMS-7-4-3.pdf

https://www.mscdirect.com/betterMRO/msc-generate-pdf/11051

https://daneshyari.com/article/preview/11263000.pdf

https://www.autocarpro.in/news-national/bajaj-auto%E2%80%99s-chakan-plant-bags-advanced-tpm-award-57036

https://www.mahindra.com/news-room/knowledge-centre/impact-stories/m-and-m-s-farm-equipment-sector-bags-advanced-special-award-for-tpm

https://www.industr.com/en/jishu-hozen-autonomous-maintenance-in-the-manufacturing-industry-2541742

https://pubmed.ncbi.nlm.nih.gov/32322743/

https://jcgirm.com/wp-content/uploads/2020/10/5-JCGIRM-2015-Vol-2-issue-3-pp-67-79.pdf

http://journal.feb.unpad.ac.id/index.php/jbm/article/view/280

https://www.irjet.net/archives/V7/i3/IRJET-V7I3663.pdf

https://www.taylorfrancis.com/books/mono/10.4324/9781315137971/autonomous-maintenance-seven-steps-masaji-tajiri-fumio-gotoh

https://www.austar.com.hk/index.php?c=skill&a=index&son_id=555&cate_id=223&id=60

https://repositorioacademico.upc.edu.pe/handle/10757/652482

https://newsstellar.com/article/the-complete-guide-to-calculating-total-manufacturing-costs-unleashed-software

December 2020

______________

https://www.youtube.com/watch?v=tTb26nBuBU4

______________

1991 - 2000

https://www.emerald.com/insight/content/doi/10.1108/13552519710167692/full/html

https://www.emerald.com/insight/content/doi/10.1108/02656710810890890/full/pdf?title=total-productive-maintenance-literature-review-and-directions

https://elsmar.com/pdf_files/TPM.pdf

https://www.iosrjournals.org/iosr-jmce/papers/ICAET-2014/me/volume-3/8.pdf?id=7622

https://books.google.co.in/books/about/TPM_A_Route_to_World_Class_Performance.html?hl=fr&id=sqP9xmLgp5IC&redir_esc=y

http://psasir.upm.edu.my/8110/1/GSM_1998_23_A.pdf

https://www.ijert.org/research/lean-manufacturing-an-approach-for-waste-elimination-IJERTV4IS040817.pdf

http://www2.uwstout.edu/content/lib/thesis/1999/1999cook.pdf

http://www.anpad.org.br/admin/pdf/gol493.pdf

http://www.egyankosh.ac.in/bitstream/123456789/12470/1/Unit-6.pdf

https://ieeexplore.ieee.org/iel7/7113953/7123067/07123145.pdf

https://books.google.co.in/books/about/Maintenance_Strategy.html?id=aA8hsS0867cC

https://dspace.lib.cranfield.ac.uk/bitstream/1826/4603/1/Richard_M_Greenough_Thesis_1999.pdf

https://asmedigitalcollection.asme.org/CES/proceedings-pdf/CEC1997/99847/27/2370748/cec1997-4303.pdf

https://reliabilityweb.com/articles/entry/the_abcs_of_failure_getting_rid_of_the_noise_in_your_system

https://www.controlglobal.com/assets/Media/MediaManager/ReducingOperationsAndMaintenanceCosts.pdf

https://www.plant-maintenance.com/change.shtml

https://books.google.co.in/books/about/Gemba_Kaizen_A_Commonsense_Low_Cost_Appr.html?id=USZrSZXmYBkC&redir_esc=y    Masaki Imai

http://archives.digitaltoday.in/businesstoday/22071999/cover.html

https://www.nber.org/system/files/working_papers/w7285/w7285.pdf

https://www.mckinsey.com/~/media/McKinsey/Business%20Functions/Economic%20Studies%20TEMP/Our%20Insights/Manufacturing%20productivity/MGI_Manufacturing_productivity_Report.pdf

https://leanconstruction.org/uploads/wp/media/docs/Koskela-TR72.pdf

https://www.elsevier.com/books/maintenance-strategy/kelly/978-0-08-093839-4

https://www.sqa.org.uk/files/hn/d2580549.pdf

https://www.delphisuppliers.com/vendor_documents/delphi-h/BlueBook/02%20Manufacturing%20Engineering/2C%20Lean%20Equipment%20Design%20Guides/Lean%20Equipment%20Design%20Guide%202nd%20print.pdf

https://www.taylorfrancis.com/books/mono/10.4324/9780367807726/5s-operators-hiroyuki-hirano

https://dtek.karnataka.gov.in/storage/pdf-files/Syllabus%20C-15/MY%20C-15%205%20and%206.pdf

Diploma course in mech. full curriculum - Karnataka State.

https://digital.library.unt.edu/ark:/67531/metadc277695/m2/1/high_res_d/1002727156-kaynak.pdf

https://eprints.nottingham.ac.uk/11470/1/301664.pdf

http://www.emeraldinsight.com/doi/abs/10.1108/00251749510093888

https://www.ptonline.com/articles/15-ways-to-raise-blown-film-productivity-without-breaking-the-bank

http://scholarworks.rit.edu/cgi/viewcontent.cgi?article=8426&context=theses

https://research.library.mun.ca/1343/1/Wong_Daniel.pdf

https://pdf.usaid.gov/pdf_docs/pnabp296.pdf

https://www.pc.gov.au/inquiries/completed/black-coal/benchmarking/tasmanasiapacific.pdf

https://smallbusiness.chron.com/productivity-plan-19095.html

https://irdproducts.com/assets/introductiontovibrationtechnology.pdf

https://www.nap.edu/read/6369/chapter/8

1981-1990

https://hbr.org/1986/09/why-some-factories-are-more-productive-than-others

https://books.google.com/books/about/New_Manufacturing_Challenge.html?id=6EHtJE8NHD0C

https://www.emerald.com/insight/content/doi/10.1108/eb054835/full/pdf?title=productivity-measurement-in-a-manufacturing-company

https://www.osti.gov/servlets/purl/7228787

https://www.bls.gov/opub/mlr/1982/06/art1full.pdf

https://www.bls.gov/mfp/trends_in_multifactor_productivity.pdf

https://www.jstor.org/stable/25060699

https://rosap.ntl.bts.gov/view/dot/18966/dot_18966_DS1.pdf?

https://sloanreview.mit.edu/article/manufacturing-innovation-lessons-from-the-japanese-auto-industry/

https://www.fs.fed.us/pnw/pubs/pnw_rp430.pdf   Analysis of new harvesting technology

https://www.treca.org/furn./margin/reliability_evaluation_of_engineering_systems_solution_pdf

https://spiral.imperial.ac.uk/bitstream/10044/1/47254/2/Shein-A-1988-MPhil-Thesis.pdf   Shovel truck productivity

http://files.eric.ed.gov/fulltext/ED311650.pdf

https://vtechworks.lib.vt.edu/bitstream/handle/10919/39114/LD5655.V856_1990.P563.pdf?sequence=1

https://dash.harvard.edu/bitstream/handle/1/30703977/w0722.pdf?sequence=1&isAllowed=y

http://pure.iiasa.ac.at/3420/1/WP-90-032.pdf

https://www.ri.cmu.edu/pub_files/pub3/ayres_robert_1981_1/ayres_robert_1981_1.pdf  impact of robots

http://etheses.whiterose.ac.uk/14611/1/238684-VOL1.pdf

1971 - 1980

https://www.wbdg.org/FFC/ARMYCOE/COETM/tm_5_610.pdf

https://research.upjohn.org/cgi/viewcontent.cgi?article=1154&context=up_press

https://hbr.org/1971/03/what-we-can-learn-from-japanese-management  

https://hbr.org/1980/03/let-first-level-supervisors-do-their-job

http://www.omdec.com/wikifiles/nowlanHeap.pdf

http://www.diva-portal.org/smash/get/diva2:1326454/FULLTEXT02.pdf

https://rosap.ntl.bts.gov/view/dot/406/dot_406_DS1.pdf?

https://files.eric.ed.gov/fulltext/ED084361.pdf

https://shareok.org/bitstream/handle/11244/19121/Thesis-1977-M515s.pdf?sequence=1  About sewing machine

https://www.ifn.se/wfiles/wp/wp017.pdf

https://www.jstor.org/stable/43294322  About Taylor

https://dspace.mit.edu/bitstream/handle/1721.1/35236/MIT-EL-78-041-06569951.pdf?sequence=1

https://www.hitachicm.us/includes/documents/brochures/KL-EN146NA-US_ZW50-80_04_21_G4_To_Print.pdf

https://web.njit.edu/~turoff/pubs/delphibook/delphibook.pdf   Delphi method

http://pdf.usaid.gov/pdf_docs/PNAAM423.pdf

https://smartech.gatech.edu/bitstream/handle/1853/24516/rezai_soheil_197608_ms_100647.pdf

Ud. 5.8.2025

Pub. 8.2.2022

Total Productive Maintenance - Nakajima - JIPM - Japan Management Association

Total Productive Maintenance - Nakajima

(Note in the Training Material for the Course Conducted by me in 1994 for ONGC in the subject of Managerial Economics and Costing for Engineers

The Definition of TPM

The Spread of TPM in Japan

How do TPM and TQC Differ?

The Basic Concepts of TPM

1. Maximizing Overall Equipment Effectiveness

2. Autonomous Maintenance

In factory automation, production workers do not have to operate machines themselves. These operators asked to oversee machines can do inspection of the automatic machines every day or week as per a plan and do routine maintenance. Specialist maintenance persons can act as equipment doctors, who periodically do expert diagnostic checks and do the required maintenance.

3. Small Group Activities in Maintenance

Similar to quality circles, zero defect movement groups and Jishu Kanri.

Program for Evolving TPM

1. Five Activities - Pillars

2.Twelve Steps to Evolve TPM

Maximizing Overall Equipment Effectiveness

Eliminating Six Big Losses

Autonomous Maintenance

Small Group Activities in Maintenance

Education and Training for Evolving TPM

‘Jishu Kanri’ activities in the Japanese steel industry Small group activities being promoted by the industry as a whole

HIDEO SUGISAWA &KAZUO HIROSE

International Journal of Production Research, Volume 15, 1977 - Issue 6, Pages 523-538

The group activities called ‘ Jishu Kanri ’ by foremen and workers in the forefront of production has been actively promoted in the Japanese Steel Industry by establishing a committee for ’ Jishu Kanri’ activities in the Japan Iron and Steel Federation, with the positive cooperation of its member companies. Nearly 8 years have elapsed since the establishment of this committee, and during this period the ability and skill of the group leaders and members in managing group activities and their awareness of problems and solutions have been greatly improved, thereby contributing much to the improvement of quality, attainment of production targets, reduction in the production costs, and improvement of safety.

https://www.tandfonline.com/doi/abs/10.1080/00207547708943147?journalCode=tprs20

The Japan Iron & Steel Federation adopted the name "Jishu-Kanri GK) Activities" to generalize the uniqueness of small group activities in this industry. JK activities are defined as "continuous group activities in which individual workers voluntarily organize small groups, select leaders from among themselves, hold discussions on an equal footing, and with their leaders as the nuclei, take up problems at the workshop, set goals for the solution of the problems, and make efforts to achieve the goals with participation by everyone".

Workers' voluntary problem solving activities cover a wide range such as product quality enhancement, efficiency improvement, cost reduction, promoting safety at the workshop, and others. In 1983, ensuring work safety was the top of activity (27.4%). About 90% of the activities in 1993 related to four areas: 

efficiency improvement (30.8%), cost reduction (24.6%), ensuring work safety (19.6%) and product quality enhancement (14.6%).

Innovation and Jishu Kanri Activities in the Japanese Steel Industry,

YONEYAMA, Kikuji,

ECONOMIC JOURNAL OF HOKKAIDO UNIVERSITY, 24, 25-58

1995

Doc URL:   http://hdl.handle.net/2115/30527

jishu 自主, じしゅ

自 oneself

主 master, 

Jishu  - mean by himself as per his decision

Jishu kanri is managing by himself, or his decisions

https://nihongomaster.com/japanese/dictionary/word/30338/jishu#:~:text=lord%2C%20chief%2C%20master%2C%20main%20thing%2C%20principal

Hoshin Kanri

Hoshin means direction and Kanri means management in Japanese.

https://kanbanize.com/lean-management/hoshin-kanri/what-is-hoshin-kanri

Hoshin Kanri 7 steps

Vision

The company's leadership develops a strong vision answering the question “Why does the company exist?”.

Objectives

The leadership team defines key objectives or also a mission. If achieved, they will create a competitive edge for the company. These are major objectives usually requiring every person's effort in the company, not monthly or quarterly objectives.

Annual Goals

The leadership team, along with the senior management, breaks down the objectives into annual goals.

Goal Setting for Various Levels and Departments

Once the annual goals are crafted, they need to be “deployed” across all levels of the organization. This is the process of “goal-setting,” which starts at the top and is propagated to each employee.

Implement Annual Objectives

With the next step, the real execution starts. This step goes hand in hand with the next two.

Monthly Review

The monthly reviews make sure that the plan is being executed according to the plan.

Annual Review

At the end of the year, there is an annual review, which validates the end result that has been achieved.

https://iopscience.iop.org/article/10.1088/1742-6596/1179/1/012089

https://books.google.co.in/books?id=bkhKaEspqaEC

2021

TPM Philosophy

https://www.youtube.com/watch?v=1hGbvo6DzRQ

2013

___________________________

https://www.youtube.com/watch?v=sZezLYax8E0

___________________________

Tsutomu Nakamura, General Manager, Japan Institute of Plant Maintenance
Presentation at Chennai, 12 September, 2013

http://tpmclubindia.org/pdf/2013/Japan_Institute_Plant_Manintenance.pdf


1961 Japan Management Association established plant maintenance department.

1971 TPM was proclaimed.

1981 Japan Institute of Plant Maintenance was launched.


https://jipmglobal.com/about/tpm

WHAT IS TPM?

TPM (Total Productive Maintenance) is a holistic approach to equipment maintenance that strives to achieve effectiveness and efficiency in the use of machines by maximizing availability and by maximizing quality output from each machine hour.

The objectives or aims of TPM are:

No Accidents
No Breakdowns
No Small Stops or Slow Running
No Defects



TPM emphasizes proactive and preventative maintenance to maximize the operational effectiveness and  efficiency of equipment. In focusing on productive availability and use of machines, it places  a strong emphasis on involving operators to help maintain their equipment.

The implementation of a TPM program creates a shared responsibility for equipment that encourages greater involvement by plant floor workers in regular cleaning, lubrication and other routine machine upkeep activities. Operators also inform machine condition frequently so that maintenance can be undertaken in timely manner. TPM became effective in many companies in improving productivity (increasing up time, reducing cycle times, and eliminating defects).

8 Pillars of TPM

Autonomous Maintenance

Places responsibility for routine maintenance, such as cleaning, lubricating, and inspection, in the hands of operators.
Gives operators greater “ownership” of their equipment.
Increases operators’ knowledge of their equipment.
Ensures equipment is well-cleaned and lubricated.
Identifies emergent issues before they become failures.
Frees maintenance personnel for higher-level tasks.

Planned Maintenance

Schedules maintenance tasks based on predicted and/or measured failure rates.
Significantly reduces instances of unplanned stop time.
Enables most maintenance to be planned for times when equipment is not scheduled for production.
Reduces inventory through better control of wear-prone and failure-prone parts.

Quality Maintenance

Design error detection and prevention into production processes. Apply Root Cause Analysis to eliminate recurring sources of quality defects.
Specifically targets quality issues with improvement projects focused on removing root sources of defects.
Reduces number of defects.
Reduces cost by catching defects early (it is expensive and unreliable to find defects through inspection).

Focused Improvement

Have small groups of employees work together proactively to achieve regular, incremental improvements in equipment operation.
Recurring problems are identified and resolved by cross-functional teams.
Combines the collective talents of a company to create an engine for continuous improvement.

Early Equipment Management

Directs practical knowledge and understanding of manufacturing equipment gained through TPM towards improving the design of new equipment.
New equipment reaches planned performance levels much faster due to fewer startup issues.
Maintenance is simpler and more robust due to practical review and employee involvement prior to installation.

Training and Education

Fill in knowledge gaps necessary to achieve TPM goals. Applies to operators, maintenance personnel and managers.
Operators develop skills to routinely maintain equipment and identify emerging problems.
Maintenance personnel learn techniques for proactive and preventative maintenance.
Managers are trained on TPM principles as well as on employee coaching and development.

Safety, Health, Environment

Maintain a safe and healthy working environment.
Eliminates potential health and safety risks, resulting in a safer workplace.
Specifically targets the goal of an accident-free workplace.

TPM in Administration

Apply TPM techniques to administrative functions.
Extends TPM benefits beyond the plant floor by addressing waste in administrative functions.
Supports production through improved administrative operations (e.g. order processing, procurement, and scheduling).


Source:  https://www.leanproduction.com/tpm.html

Six Big Losses

Unplanned Stops Availability Loss
Tooling Failure, Unplanned Maintenance, Overheated Bearing, Motor Failure There is flexibility on where to set the threshold between an Unplanned Stop (Availability Loss) and a Small Stop (Performance Loss).

Setup and Adjustments Availability Loss
Setup/Changeover, Material Shortage, Operator Shortage, Major Adjustment, Warm-Up Time This loss is often addressed through setup time reduction programs such as SMED (Single-Minute Exchange of Die).

Small Stops Performance Loss
Component Jam, Minor Adjustment, Sensor Blocked, Delivery Blocked, Cleaning/Checking Typically only includes stops that are less than five minutes and that do not require maintenance personnel.

Slow Running Performance Loss
Incorrect Setting, Equipment Wear, Alignment Problem Anything that keeps the equipment from running at its theoretical maximum speed.

Production Defects Quality Loss
Scrap, Rework Rejects during steady-state production.

Reduced Yield Quality Loss
Scrap, Rework Rejects during warm-up, startup or other early production.

Source:  https://www.leanproduction.com/tpm.html


TPM - Good Presentation
http://www.authorstream.com/Presentation/kececimehmet-2116331-tpm/

Seiichi Nakajima

TPM - Note Included in ONGC Course on Maintenance ( Sep 12 to 17, 1994 coordinators, Prof. Narayana Rao, & Prof. Hedge)

https://www.efficientplantmag.com/2015/06/remembering-the-father-of-tpm/

https://oee.academy/oee-academy/history-of-oee-and-tpm/

https://www.linkedin.com/pulse/what-tpm-how-implement-benefits-implementing-aryan-viswakarma/

https://www.academia.edu/20808937/Implementing_Total_productive_Maintenance_learning_from_two_companies

Implementing TPM: The North American Experience

Andrew Ginder, Alan Robinson, Charles J. Robinson

CRC Press, 26-Aug-2020 - Business & Economics - 224 pages

This book provides an understanding of the complexity and comprehensiveness of the total productive maintenance (TPM) process. It supplements works by Japanese authors with guidance and detail on how the TPM process relates to North American plants or facilities.

https://books.google.co.in/books?id=O2H4DwAAQBAJ

Systematic Industrial Maintenance to Boost the Quality Management Programs

Adnan Bakri, Mohd Al-Fatihhi Mohd Szali Januddi

Springer Nature, 04-Jun-2020 - Technology & Engineering - 78 pages

This book discusses the main quality management (QM) programs and their possible integration into systematic industrial maintenance (SIM). Unlike traditional engineering maintenance books, it not only explains the theory but also provides practical examples of the integration of QM and SIM programs. It also includes reference sources, making it useful for readers wanting to explore specific areas in more depth.

Chapter 1 introduces various aspects of the main quality management (QM) programs, including total quality management (TQM), just-in-time (JIT) and lean manufacturing (Lean). Subsequently, it examines the relation of quality and maintenance. Chapter 2 reviews the concepts of systematic industrial maintenance (SIM) and the application of quality control (QC) tools. Chapter 3 offers an overview, historical perspective and trends in industrial maintenance techniques. Chapters 4, 5, 6, 7, 8 and 9 focus on topics related to schedule-based maintenance, condition-based maintenance, reliability-based maintenance, computerized-based maintenance, risk-based maintenance and total productive maintenance. Covering the theory of each of these types of SIM, the chapters also explain their real-world application in QM and highlight their merits and weaknesses in the context of supporting QM.

https://books.google.co.in/books?id=xXHpDwAAQBAJ

2008

https://economictimes.indiatimes.com/news/company/corporate-trends/132-indian-manufacturing-cos-join-tpm-excellence-league/articleshow/2875307.cms?from=mdr

Updated on 5.8.2025,  4.2.2022,  20 May 2020,  5 June 2019. 18 December 2013

Maintenance for Boom Placers : Maximizing Performance and Extending Lifespan

 

Maintenance Tips for Boom Placers : Maximizing Performance and Extending Lifespan

https://pinakins.in/maintenance-tips-for-boom-placers/

Kobetsu Kaizen - Focused Improvement of Machine and Machine Work in TPM

 

An interesting article

https://www.linkedin.com/pulse/step-by-step-focused-improvement-approach-kobetsu-kaizen-fidanc%C4%B1-/

https://www.linkedin.com/pulse/relation-focused-improvement-pillar-other-pillars-kobetsu-fidanc%C4%B1-/

https://www.linkedin.com/pulse/low-cost-kaizens-kobetsu-kaizen-approach-raku-toku-g%C3%B6khan-fidanc%C4%B1-/

https://www.linkedin.com/pulse/how-do-we-zero-breakdown-loss-kobetsu-kaizen-project-g%C3%B6khan-fidanc%C4%B1-/

https://www.linkedin.com/pulse/how-implement-focused-improvement-kobetsu-kaizen-g%C3%B6khan-fidanc%C4%B1-/

https://www.linkedin.com/pulse/focused-improvement-kobetsu-kaizen-g%C3%B6khan-fidanc%C4%B1-/

https://www.linkedin.com/pulse/focused-improvement-kobetsu-kaizen-g%C3%B6khan-fidanc%C4%B1--2f/

Manufacturing System Losses Identified in TPM Literature - Principles of Machine Economy

Principles of motion economy for human effort industrial engineering. Principles of machine economy for machine effort industrial engineering.

Principles of Machine Economy

• Minimize the machine time and speed losses
• Definition of 16 Major losses

A.    Seven major losses that impede overall equipment efficiency

1 Failure losses (Breakdown) Losses due to failures.
Types of failures include sporadic function-stopping failures, and function-reduction failures in which the function of the equipment drops below normal levels.

2 Set up and adjustment losses
Stoppage losses that accompany set-up changeovers

3 Cutting blade change losses
Stoppage losses caused by changing the cutting blade due to breakage, or caused by changing the cutting blade when the service life of the grinding stone, cutter or bite has been reached.

4 Start-up losses
When starting production, the losses that arise until equipment start-up, running-in and production processing conditions stabilize.

5 Minor stoppage and idling losses

Losses that occur when the equipment temporarily stops or idles due to sensor actuation or jamming of the work. The equipment will operate normally through simple measures (removal of the work and resetting).

6 Speed losses
 Losses due to actual operating speed falling below the designed speed of the equipment.

7 Defect & rework loss
Losses due to defects & reworking

B. Losses that impede equipment loading time

8 Shutdown (SD) losses
Losses that arise from planned equipment stoppages at the production planning level in order to perform periodic inspection and statutory inspection

C. Five Major losses that impede workers efficiency

9 Management losses Waiting losses that are caused by management, such as waiting for materials, waiting for a dolly, waiting for tools, waiting for instructions etc.

10 Motion losses
Man-hour losses arising from differences in skills involved in etc.

11 Line organization losses
 Idle time losses when waiting for multiple processes or multiple platforms.

12 Distribution losses
 Distribution man-hour losses due to transport of materials, products (processed products) and dollies.

13 Measurement and adjustment losses
Work losses from frequent measurement and adjustment in order to prevent the occurrence and outflow of quality defects.

D Three major losses that impede efficient use of production subsidiary resources

                    
14 Energy losses        
 Losses due to ineffective utilization of input energy (electric, gas, fuel oil, etc) in processing.

15 Die, jig and tool losses
Financial losses (expenses incurred in production, regarding renitriding, etc.) which occur with production or
repairs of dies, jigs and tolls due to aging beyond services life or breakage.

16 Yield losses
 Material losses due to differences in the weight of the input materials and the weight of the quality products

Improvement Techniques

Source: D matrix (matrix of causal losses and their improvement techniques)

H. Yamashina & T. Kubo (2002) Manufacturing cost deployment, International

Journal of Production Research, 40:16, 4077-4091, DOI: 10.1080/00207540210157178

Individual approaches/techniques

1. Breakdown analysis

2. Setup time reduction

3. Tool life improvement

4. Startup time reduction

5. PM analysis

6. Cycle time reduction

7. Cp, Cpk improvement

8. N.V.A.A.

9. Operation method
10. Layout improvement

11. Inspection method

12. Yield improvement

13. Material saving method

14. Energy saving method

Systematic approaches

1. Operative maintenance

2. Preventive maintenance

3. Predictive maintenance

4. Quality maintenance

5. Quality assurance

6. Education and training

Improvement techniques for losses

1. Breakdown analysis

In the first step, maintenance by production operators can be implemented to prevent the forced deterioration of each facility component. 

In the second step, individual approaches such as processing point analysis and so on are adopted to eliminate causes of the breakdown. 

In the third step, preventive maintenance is implemented to do planned maintenance of facility components regularly. 

Finally, predictive maintenance is implemented using various kinds of diagnostic technology in the forth step. 

In addition to these steps, breakdown and repair rates are further reduced through improvement in skill of maintenance workers, etc. 

There are several steps and approaches in each of the improvement of activities. Therefore, the most appropriate technique corresponding to the condition of each facility must be selected. 

Improvement activities for losses associated with operators. Losses of man-hours are reduced through, for example, confirmations in operating methods, improvements in plant layouts (to reduce movementof operators), automation with the introduction of robots, etc.

Improvement activities for losses associated with material, etc. In reducing yield loss, for example, activities such as design changes increase the yield ratio. One example of improvement approaches in

indirect material loss is to reduce unit prices by decreasing the consumption of machining lubricant and other indirect materials. 

In case of improvements about die and jig losses, cost reduction is possible by, for example, extending their lives through confirming their specifications. 

Examples of improvement approaches in energy loss are to increase energy efficiency by reducing the down time of facilities, to decrease the unit price, etc.

More detailed descriptions of improvement techniques for the other losses are given in K. Okazaki (1996).

Focused Equipment Improvement for TPM Teams

Japan Institute of Plant Maintenance

Routledge, 13-Nov-2017 - Business & Economics - 142 pages

As distinguished from autonomous maintenance, where the main goal is to restore basic conditions of cleanliness, lubrication, and proper fastening to prevent accelerated deterioration, FEI looks at specific losses or design weaknesses that everyone previously thought they just had to live with. Once your TPM operator teams are progressing with their daily autonomous maintenance activities, you will want to take the next advanced step in TPM training with this book.

Key Features:

• A simple and powerful introduction to P-M Analysis
• hints for unraveling breakdown analysis
• numerous ideas for simplifying and shortening setups
• ideas for eliminating minor stoppages and speed losses
• basic concepts of building quality into processing
• real-life examples from a leading Japanese tool company
• Educate and empower all your workers to support your TPM improvement activities. 

This book discusses in detail 5 of the 6 big losses discussed in TPM literature.

https://books.google.co.in/books?id=H2Q-DwAAQBAJ

TPM: Collected Practices and Cases

Productivity Press

CRC Press, 13-Feb-2019 - Business & Economics - 140 pages

Equipment downtime can bring a lean manufacturing operation to a complete standstill. Total productive maintenance (TPM) is such a fundamental part of becoming lean because a machine failure at one step of a continuous flow process will halt all the steps before and after it.

https://books.google.co.in/books?id=eNc5byKalbsC

16 Big Losses in Production and Ways to Minimize Them

https://www.olanabconsults.com/articles/16-big-losses-in-production-and-how-to-prevent-them

Taylor's Industrial Engineering - Machine Utilization Economy 

Principles of Machine Productivity - F.W. Taylor

1. A careful study is to made of the time required to do each of the many elementary operations of machining of components manufactured in the establishment.
2.These elementary operations are then classified, recorded, and indexed, and when work is to be done,  the job is first divided into its elementary operations, the time required to do each elementary operation is found from the records, and the total time for the job is summed up from these data.
3. This method is more effective than the method of estimating the time based on time taken to do whole jobs of similar components.
4. To implement the principles, in the case of work done by metal-cutting tools, such as lathes, planers, boring mills, etc., F.W. Taylor undertook a long and expensive series of experiments  to determine, formulate, and finally practically apply to each machine the law governing the proper cutting speed of tools, namely, the effect on the cutting speed of altering any one of the following variables : the shape of the tool (i.e., lip angle, clearance angle, and the line of the cutting edge), the duration of the cut, the quality or hardness of the metal being cut, the depth of the cut, and the thickness of the feed or shaving.
5. The careful study of the capabilities of the machines and the analysis of the speeds at which they must run is to be made.
6. Defects or shortcoming in machines will be realized when the best methods of cutting metals are determined and the necessary modifications have to be made, if possible. Otherwise, replacement needs to be done at the earliest economic opportunity.
7. Systematization of many small details in the running of the machine shop, such as the care of belting, the proper shape for cutting tools, and the dressing, grinding, and issuing tools, oiling machines, issuing orders for work,  and a host of other minor methods and processes which may waste a machinist's time or machine time.
8. The care of the equipment is to be improved.

Machine Utilization Principle of Industrial Engineering - Prof. Ralph Barnes

1. Few people advocate using human labor to do work that can be done better and cheaper by machines.

2. It is suggested that the best manual method and the best combination of manual and machine method (mechanized) be developed and used as a basis for evaluating a proposed automated process.

(Restated as: Compare best manual method, mechanized method and automated method for each element of an operation and choose the best.)

3. If a large-volume fairly complex job is to be considered, a comparison would be of the estimated cost to do each element of each suboperation manually, or in machanized way, or automatically.

Ralph Barnes is the first PhD in Industrial Engineering. He wrote the popular text, Motion and Time Study.

Industrial engineers have to learn mechanization and automation that is engineering very well and use it in industrial engineering to provide increased support of machines to people to increase their productivity and standard of living.

Machine Utilization Principles - Nakajima

Total Productive Maintenance - Nakajima

(Note in the Training Material for the Course Conducted by me in 1994 for ONGC in the subject of Managerial Economics and Costing for Engineers

The Definition of TPM

The Spread of TPM in Japan

How do TPM and TQC Differ?

The Basic Concepts of TPM

1. Maximizing Overall Equipment Effectiveness

2. Autonomous Maintenance

In factory automation, production workers do not have to operate machines themselves. These operators asked to oversee machines can do inspection of the automatic machines every day or week as per a plan and do routine maintenance. Specialist maintenance persons can act as equipment doctors, who periodically do expert diagnostic checks and do the required maintenance.

3. Small Group Activities in Maintenance

Similar to quality circles, zero defect movement groups and Jishu Kanri.

Program for Evolving TPM

1. Five Activities - Pillars

2.Twelve Steps to Evolve TPM

Maximizing Overall Equipment Effectiveness

Eliminating Six Big Losses

Autonomous Maintenance

Small Group Activities in Maintenance

Education and Training for Evolving TPM

‘Jishu Kanri’ activities in the Japanese steel industry Small group activities being promoted by the industry as a whole

HIDEO SUGISAWA &KAZUO HIROSE

International Journal of Production Research, Volume 15, 1977 - Issue 6, Pages 523-538

The group activities called ‘ Jishu Kanri ’ by foremen and workers in the forefront of production has been actively promoted in the Japanese Steel Industry by establishing a committee for ’ Jishu Kanri’ activities in the Japan Iron and Steel Federation, with the positive cooperation of its member companies. Nearly 8 years have elapsed since the establishment of this committee, and during this period the ability and skill of the group leaders and members in managing group activities and their awareness of problems and solutions have been greatly improved, thereby contributing much to the improvement of quality, attainment of production targets, reduction in the production costs, and improvement of safety.

https://www.tandfonline.com/doi/abs/10.1080/00207547708943147?journalCode=tprs20

The Japan Iron & Steel Federation adopted the name "Jishu-Kanri GK) Activities" to generalize the uniqueness of small group activities in this industry. JK activities are defined as "continuous group activities in which individual workers voluntarily organize small groups, select leaders from among themselves, hold discussions on an equal footing, and with their leaders as the nuclei, take up problems at the workshop, set goals for the solution of the problems, and make efforts to achieve the goals with participation by everyone".

Workers' voluntary problem solving activities cover a wide range such as product quality enhancement, efficiency improvement, cost reduction, promoting safety at the workshop, and others. In 1983, ensuring work safety was the top of activity (27.4%). About 90% of the activities in 1993 related to four areas: 

efficiency improvement (30.8%), cost reduction (24.6%), ensuring work safety (19.6%) and product quality enhancement (14.6%).

Innovation and Jishu Kanri Activities in the Japanese Steel Industry,

YONEYAMA, Kikuji,

ECONOMIC JOURNAL OF HOKKAIDO UNIVERSITY, 24, 25-58

1995

Doc URL:   http://hdl.handle.net/2115/30527

jishu 自主, じしゅ

自 oneself

主 master, 

Jishu  - mean by himself as per his decision

Jishu kanri is managing by himself, or his decisions

https://nihongomaster.com/japanese/dictionary/word/30338/jishu#:~:text=lord%2C%20chief%2C%20master%2C%20main%20thing%2C%20principal

Hoshin Kanri

Hoshin means direction and Kanri means management in Japanese.

https://kanbanize.com/lean-management/hoshin-kanri/what-is-hoshin-kanri

https://iopscience.iop.org/article/10.1088/1742-6596/1179/1/012089

https://books.google.co.in/books?id=bkhKaEspqaEC

Machine Work Study to Promote Machine Utilization Economy 

Machine Work Study was proposed by Narayana Rao to emphasize the need to study the machine and its engineering elements as part of industrial engineering studies. Machine work study is related to the machine or tool and its proper use like motion study is related to the man and his motions to do work with tools or completely with hands. The issues to be covered in machine work study are already structured in books on metal cutting and machine tools. The productivity dimension of the metal cutting theory has to be covered in machine work study and methodology is to be provided for doing machine work study. Operation analysis by Maynard and Stegemerten provides the basic framework for doing machine work study.

Machine Shop Process Industrial Engineering

Machine Shop Process Industrial Engineering that includes all focus areas industrial engineering is presented in a separate article.

Productivity Science
Productivity Science of Machining - Stephenson - Agapiou
IE Measurements
Process Industrial Engineering - Process Alternatives and Economic Analysis of IE Proposed Alternatives
IEOR - Optimization in Machining Processes
IE Statistics Optimization - Six Sigma Method
Human Effort Engineering in Machine Shop
Applied Industrial Engineering in Machine Shop
https://nraoiekc.blogspot.com/2020/04/machine-shop-process-industrial.html

Improving Machine Capacity Utilization by Hemant Patil

https://www.linkedin.com/in/hemant-patil-industrial-engineer/

https://industryreadyskills.com/blogs/f/improving-machine-capacity-utilization

Original knol - http://knol.google.com/k/narayana-rao/manufacturing-system-losses-idenfied-in/ 2utb2lsm2k7a/ 3211



Updated on 6.5.2022,  10 Feb 2021, 24 August 2019, 20 April 2012

News - Information for Maintenance Operation Industrial Engineering Analysis

Maintenance System Industrial Engineering

Process Improvement using engineering knowledge to reduce cost through increasing productivity of machines and men by reducing machine time and man time is the main activity of industrial engineering.

Many other disciplines help industrial engineers to achieve their objectives. But the main discipline that is the foundation for IE is engineering of products and processes.

Process chart can be prepared for equipment also. This is what was mentioned by an author. But one does not see examples of process charts with equipment as the focus.

Equipment can be under operation, breakdown/maintenance, setup, idle time due to lack of material, idle time due to lack electrical power, idle time due to lack of tools, idle time due to lack of operator etc.  Hence, in normal process charts, temporary delays include delays due to equipment breakdowns. Individual equipment maintenance may need to be investigated under process improvement studies of various parts and assembly. Overall maintenance policies will affect or improve all processes.

The field of maintenance expanded so fast, and in smart plants, the outcome industrial revolution 4.0, predictive maintenance is an important activity. Development in predictive maintenance is far ahead of application of IoT in the manufacturing process. Industrial engineers have to keep track of developments in the maintenance field to utilize them as early as needed in their process improvement activity, process industrial engineering.

Process Industrial Engineering - Methods and Techniques

--------------------------------------------------------------------------------

SOPs for Maintenance

https://zoidii.com/blogpost/standard-operating-procedures-for-maintenance

2021

Checklist -  Top Preventive Maintenance Tips for Your CNC Machine Tools

by Hwacheon Asia - Aug 6, 2021.

https://hwacheonasia.com/checklist-top-preventive-maintenance-tips-for-your-cnc-machine-tools/

Preventive Maintenance Checklist

(Schedule regular maintenance or servicing sessions, and maintain documentation of service/maintenance. Also, have a specific area for your employees to report issues.)

MECHANICAL SYSTEM

Verify machine level

VMC – verify spindle sweep

Lathe – verify turret square to spindle face

Check lubrication is reaching the spindle

Inspect rotary oil level (mill)

Inspect drive belts

Verify gearbox/motor operation

Inspect tool changer and lubricate

Inspect spindle taper condition (mill)

Inspect toolholders and grease pull studs (mill)

Verify smooth turret indexing (lathe)

 LUBRICATION SYSTEM 

Inspect filter

Inspect hoses and fittings

Check pump operation / test

Check/adjust pressure, spindle regulator

Inspect system for leaks

Change gearbox oil (lathe only)

Change hydraulic fluid and filter 

ELECTRICAL SYSTEM

Clean electrical cabinet

Check incoming voltages

Check DC bus voltage

Inspect connections and terminals

Inspect electrical ground connections

Replace or clean filter fan

Check safety locks

Check axis motors and cables

COOLANT SYSTEM

Inspect coolant hoses

Verify all pump operation

Clean coolant filters

Test and adjust coolant concentration

Inspect coolant tank for sediment

AIR & LUBRICATION SYSTEM

Inspect all lines and hoses

Verify all pump operation

Check incoming air supply

Verify lube/pump operation for axes

MECHANICAL SYSTEM:

Inspect tool holders/grease pull studs.

Inspect the rotary oil level (Mill)

ENCLOSURE/SAFETY:

Inspect safety interlock operation

Inspect windows for damage

Inspect way covers and wipers

PROBE SYSTEM:

Check the probe batteries

Check probe calibration

https://www.haascnc.com/service/Preventive_Maintenance.HTML.html

Monitoring the condition of the spindles: Sensemore uses Trigger device. Trigger sends the measurement order to the sensor by transmitting the 5V signals to the receiver with a code to be returned at the end of each process. Thus, it can monitor the vibrations of a CNC lathe in the grinding wheel spindle at the end of each machining and in a way that the parameters remain the same in every measurement.

Operating the grinding wheel spindle at a constant speed for a short time at the end of each machining and taking vibration measurements during this process will create a correct trend as it is within certain boundary conditions. The code added to the CNC lathe sends a 5V signal to the Sensemore Trigger device after each part is machined. Sensemore Trigger gives the measurement order by triggering the Wired with the signal it receives. The whole process is completed in as little as five seconds and analyzes are performed on the Sensemore cloud application.  

Nowadays, maintenance, and quality processes are carried out in an automated manner. . Sensemore, thanks to the portable accelerometers, application-specific hardware, and cloud-based analysis program they developed, offer easier and more reliable automated maintenance and quality control processes.

https://sensemore.io/condition-monitoring-in-cnc-machines-and-case-study/

Troubleshooting CNC Breakdowns and Steps to Avoid Them

March 22, 2021

https://www.americanmachinist.com/shop-operations/article/21158732/troubleshooting-cnc-breakdowns-and-steps-to-avoid-them-fictiv

Industry 4.0 in CNC Machine Monitoring

https://www.faststreamtech.com/blog/industry-4-0-in-cnc-machine-monitoring/

Predictive Maintenance Case Studies 

https://www.faststreamtech.com/casestudies/predictive-maintenance/

June 2020

SAP Predictive Maintenance and Service
Combine sensor data with business information in your ERP, customer relationship management (CRM), enterprise asset management (EAM), and augmented reality systems using SAP Predictive Maintenance and Service, part of the SAP Intelligent Asset Management solution portfolio.

Cloud and on-premise deployment
Insight from sensor data
Prediction of equipment malfunctions
Optimized resource management
https://www.sap.com/hk/products/predictive-maintenance.html


Azure AI guide for predictive maintenance solutions
01/10/2020
42 minutes to read
https://docs.microsoft.com/en-us/azure/machine-learning/team-data-science-process/predictive-maintenance-playbook

2019

Submitted on 12 Dec 2019
A Survey of Predictive Maintenance: Systems, Purposes and Approaches
Yongyi Ran, Xin Zhou, Pengfeng Lin, Yonggang Wen, Ruilong Deng

This paper provides a comprehensive literature review on Predictive Maintenance (PdM) with emphasis on system architectures, purposes and approaches. we first provide a high-level view of the PdM system architectures including the Open System Architecture for Condition Based Monitoring (OSA-CBM), cloud-enhanced PdM system and PdM 4.0, etc. Then, we make clear the specific maintenance purposes/objectives, which mainly comprise cost minimization, availability/reliability maximization and multi-objective optimization. Furthermore, we provide a review of the existing approaches for fault diagnosis and prognosis in PdM systems that include three major subcategories: knowledge based, traditional Machine Learning (ML) based and DL based approaches. We make a brief review on the knowledge based and traditional ML based approaches applied in diverse industrial systems or components with a complete list of references, while providing a comprehensive review of DL based approaches.

https://arxiv.org/abs/1912.07383

Predictive Maintenance Services and Research from GE

Predictive Maintenance technologies aim to detect, diagnose, and predict failures and degradation in machine components prior to criticality.  The ultimate goal is to prevent downtime, identify root causes for follow-up action, and enable efficient evidence-based maintenance planning and optimization. GE Research has a rich history in the development of Predictive Maintenance technologies, with deployed tools managing over one hundred thousand assets across the GE business units as well as countless more for GE's customers in the aerospace, power generation, transportation, oil exploration, and healthcare domains.

The primary research topics being pursued by GE fall into two categories: Early Warning and Prognostics.

Early Warning pertains to detecting anomalous behaviors in a system's operation at the earliest possible time to provide the maximum lead time for any potential action.  This technology is applicable across industrial verticals and is traditionally the first item in combined Prognostics Health Management (PHM) deployments. GE Research software solutions for early warning are built around unsupervised, semi-supervised, and fully-supervised data exploration, enabling a broad span of solution complexities based upon the availability of data.  Research has included an emphasis on fusion algorithms to integrate alerts and mixed-type information from multiple models to improve prediction accuracy and lead detection time as well as reduce alert fatigue. Similarly, research activities have yielded a robust multivariate time series search pipeline to speed up human interaction when searching for signatures, features, and patterns in massive time series data (for root cause and diagnostic reporting).

Prognostics go a step further to provide long term predictions of behavior and life. Prognostic algorithms aim to forecast remaining useful life, time to reduced capability, and emergent fleet segmentation for planning inspection, maintenance, repair, and spare parts inventory. GE Research technologies in this space are built upon a suite of hybrid modeling techniques that use embodied domain physics along with condition monitoring data from fielded systems and simulations. This also allows learning systemic behaviors from entire fleets through techniques such as transfer learning. Furthermore, auto-inspection technologies allow us to inspect and label component condition (and quantify performance of associated prognostic models) without human bias, adapting the fielded models in a continuous learning mode.

GE pursuing research in the area of Predictive Maintenance seeking new frontiers in the related technologies.
https://www.ge.com/research/project/predictive-maintenance


AWS Solutions Library -  AWS Solutions Implementations  - Predictive Maintenance Using Machine Learning
What does this AWS Solutions Implementation do?

Predictive Maintenance Using Machine Learning deploys a machine learning (ML) model and an example dataset of turbofan degradation simulation data to train the model to recognize potential equipment failures. 

You can use this solution to automate the detection of potential equipment failures, and provide recommended actions to take. The solution is easy to deploy and includes an example dataset but you can modify the solution to work with any dataset.
https://aws.amazon.com/solutions/implementations/predictive-maintenance-using-machine-learning/

Strategic Maintenance Planning

Anthony Kelly

Elsevier, 28-Jun-2006 - Business & Economics - 304 pages

Strategic Maintenance Planning deals with the concepts, principles and techniques of preventive maintenance, and shows how the complexity of maintenance strategic planning can be resolved by a systematic ‘Top-Down-Bottom-Up’ approach. It explains how to establish objectives for physical assets and maintenance resources, and how to formulate an appropriate life plan for plant. It then shows how to use the life plans to formulate a preventive maintenance schedule for the plant as a whole, along with a maintenance organization and a budget to ensure that maintenance work can be resourced.

This is one of three stand-alone volumes designed to provide maintenance professionals in any sector with a better understanding of maintenance management, enabling the identification of problems and the delivery of effective solutions.

* The first of three stand-alone companion books, focusing on the formulation of strategy and the planning aspects of maintenance management

* Learn how to establish objectives - for physical assets and maintenance resources; Formulate a life plan for each unit and a preventive maintenance schedule for the plant as a whole; Design a maintenance organization and budget to ensure that the maintenance work can be resourced

* With numerous review questions, exercises and case studies - selected to ensure coverage across a wide range of industries including processing, mining, food, power generation and transmission

https://books.google.co.in/books?id=T6mrmqJNYQEC

Ud - 6.5.2022,  4.10.2021, 15.9.2021, 24 May 2021
Pub on 6 July 2020