Page 198 - DMGT524_TOTAL_QUALITY_MANAGEMENT

Unit 13: Total Productive Maintenance

Poor Quality Losses Notes

5. Process non-conformities
6. Scrap
These losses can be quantified into three metrics and can be summarized into equipment
effectiveness metric. Equations for these metrics are explained below:
Downtime losses are measured by equipment availability using the equation:
A = (T/P) × 100
Where A = availability

T = Operating time (P-D)
P = Planned operating time
D = Downtime
Reduced speed losses are measured by tracking performance efficiency using the equation

E = (C × N/T) × 100
Where E = Performance efficiency
C = Theoretical cycle time
N = Processed amount (quantity)

Poor quality losses are measured by tracking the rate of quality products using the equation
R = ((N-Q)/N) × 100
Where R = Rate of quality of products
N = Processed amount (quantity)

Q = Non-conformance
Equipment effectiveness is measured as the product of the decimal equivalent of the three
previous metrics using the equation

EE = A × E × R
Where EE = Equipment effectiveness
Or
Overall Equipment Effectiveness (OEE)

Thus improvement needs can be expresses in terms of amount of increase in OEE.

13.2.5 Setting Improvement Goals

Goals should be set for the improvement after improvement needs are identified. A time frame
for improvement project should be clearly defined. Priorities for improvement projects should
be developed. Project teams should be involved in setting these improvement goals.

13.2.6 Developing Plans

The next step in successful implementation of TPM is developing an implementation and training
program. Plans for developing autonomous work groups should take place during the training

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