Total productive maintenance and change over reduction engineering a way to increase quality and productivity

Summary form only given. Total productive maintenance (TPM) and change over reduction engineering (CORE) are fundamental parts of the just-in-time production system and a way to increase productivity and quality. The major TPM improvement activities include maximizing equipment effectiveness, eliminating the six big equipment-related losses, autonomous maintenance by operators and small group activities, training to improve operation and maintenance skills and the promotion of maintainability from the design throughout the entire life span of the equipment. Set-up and adjustment is one of the six big losses of TPM, and single minute exchange of dies (SMED) is the heart of just-in-time production. CORE, using a newly developed software, takes SMED to a new dimension. With this approach, companies have typically achieved over 50 per cent change-over reduction. Some companies are achieving success with TPM: equipment downtimes are drastically reduced, equipment productivity is strongly increased, maintenance costs are reduced, process yields and product quality dramatically improved. This paper shows the fundamentals of TPM, its successful industrial application and some selected results of maintenance benchmarking in the manufacturing and process industry, which shows the present state and future development of equipment and maintenance management. The basics and some results of CORE are presented. Typically, the results are obtained in workshops in just a few days. CORE projects were carried out in several countries