which is the best pound for pound improvement strategy vs rcm.pdf · rsa inspired by change . . ....
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Rolly Angeles
TPM vs RCM METHODOLOGY
Inspired by Change . . . RSA 2011
2011 All Rights Reserved Rev 5 : April 15, 2011
Which is the Best Pound for
Pound Improvement Strategy
Let’s Get Ready to
Rumble !
Rolly Angeles
TPM vs RCM METHODOLOGY
Inspired by Change . . . RSA 2011
RCM and TPM are two of the most well know mainte-
nance and reliability improvement known to industries.
The results of this comparison are purely based on
the authors experience and knowledge with these two
power house improvement strategies and might differ
from other expert’s opinion. I have met independent
consultants on both TPM and RCM and asked for their
individual opinion regarding the other strategy. There
always seem to be some form of bias to whomever
you talk to. One can only understand which methodolo-
gies have an edge if you truly experience them both.
2011 All Rights Reserved
W A R N I N G
Rolly Angeles
TPM vs RCM METHODOLOGY
Inspired by Change . . . RSA 2011
RCM vs TPM SURVEY QUESTION
• Are you knowledgeable on TPM or RCM ?
Write the letter in a 1/8 piece of paper, and submit to the facilitator.
The result of the survey will be sum up and given as a percentage
of the class. Answer as honest as you can.
A) Yes, I know the concept of TPM only
B) Yes, I know the concept of RCM only
C) Yes, I know both TPM and RCM concept
D) Yes, I know both of them and we are currently
practicing both RCM and TPM
E) I have totally no idea what they meant
Answer honestly which letter do you think that best
fits your situation
Rolly Angeles
TPM vs RCM METHODOLOGY
Inspired by Change . . . RSA 2011
TPM Defined :
• TPM is a plant improvement methodology
which enables continuous & rapid improve-
ment of the manufacturing process through
the use of employee involvement, employee
empowerment and closed-loop measurement
of results
Implementing TPM by Robinson and Ginder
• It is a production driven improvement metho-
dology that is designed to optimize equipment
reliability and ensure efficient management of
Plant assets
Rolly Angeles
TPM vs RCM METHODOLOGY
Inspired by Change . . . RSA 2011
TPM Composed of 8 Pillars
Autonomous
Maintenance Production & Operations
Kobetsu-Kaizen - Cross Functional Teams
- Engineers and Process
Initial Flow
Control Activities - Purchasing Group
- RND Group
Admin / Office
TPM Administrative People
Environmental
Health and Safety EHS Department
Training and
Education Training Department
Planned
Maintenance Maintenance People
Quality
Maintenance Quality Control Group
Rolly Angeles
TPM vs RCM METHODOLOGY
Inspired by Change . . . RSA 2011
Goals of Each TPM Pillar
Planned Maintenance
- Attain Predictive Mtce Stage
- Increase MTBF reduce BDO to Zero
- Improve reliability & lower costs
- Establish Basic Equipment Condition
- Develop Standards for Lubrication,
Inspection and Cleaning
- Develop Empowered Operators
Autonomous Maintenance
- Attain 85% OEE on critical machines
- Elimination of 6 Equipment Losses
- Improve indices on PQCDSM
Focused Improvement
- Zero accidents and plant disasters
- Compliance to environmental stds.
Environmental, Health
and Safety (EHS)
Quality Maintenance
- Elimination of defects
- Elimination of chronic problems
Admin/Office TPM
- Reduce of Product inventory and
Work-In-Process
- Speed of Information transmission
Initial Flow Control
Activities (IFCA) - Well develop system of MP Design
- Improvement in Vertical Start-up
time of equipment being purchase
Training and Education
- Effective training skills assessment
- Systematic training programs
- Training's are used religiously
Zero Breakdowns
Zero Accidents
Zero Defects
Rolly Angeles
TPM vs RCM METHODOLOGY
Inspired by Change . . . RSA 2011
TPM 12 Developmental Step by Step Approach
Stage Step
Preparatory 1. Declaration of Top Management to introduce TPM
2. Conduct TPM Educational Campaign
3. Create a TPM promotional organization
4. Establish TPM Basic Policy and Goals
5. Create a Master Plan of Implementing TPM
Introduction 6. Kick-off TPM
Implementation 7. Establish system to improve Production Efficiency
7.1 Implement Kobetsu-Kaizen Pillar
7.2 Implement Autonomous Maintenance Pillar
7.3 Implement Planned Maintenance Pillar
7.4 Training & education for operation and mtce
8. Build an Initial Flow Control Activities
9. Build a Quality Maintenance System
10. Implement Admin./Office TPM for support system
11. Establish a system for effective EHS
Stabilization 12. Total TPM implementation and raise level
Rolly Angeles
TPM vs RCM METHODOLOGY
Inspired by Change . . . RSA 2011
RCM EVOLVEMENT FROM THE AIRLINE INDUSTRY
• Reliability-Centred Maintenance find its roots in work done by the
international commercial aviation industry
• Driven by the need to improve reliability while containing the cost of
maintenance, this industry develop a comprehensive process for
deciding what maintenance work is needed to keep aircraft airborne.
This process evolved steadily in its early beginning during the 1960’s
• This process is still being used up to this day to determine the required
maintenance task for their assets for the commercial aviation industry
Rolly Angeles
TPM vs RCM METHODOLOGY
Inspired by Change . . . RSA 2011
Reliability -Centred Maintenance : is a process used
to determine the maintenance requirements of any
physical asset in its operating context.
Reliability -Centred Maintenance : is a process used
to determine what must be done to ensure that any
physical asset continues to do whatever its users
want it to do in its present operating context.
LIGHTER DEFENITION :
7 BASIC RCM QUESTIONS :
1. What are the functions and associated performance standards of the asset in its
present operating context ?
2. In what ways does it fail to fulfill its functions ?
3. What causes each functional failures ?
4. What happens when each functional failure occurs ?
5. In what ways does each failure matter ?
6. What can be done to predict or prevent each failure ?
7. What should be done if a suitable proactive task cannot be found ?
Rolly Angeles
TPM vs RCM METHODOLOGY
Inspired by Change . . . RSA 2011
1 How it is being approached
ROUND RCM TPM RESULTS POINT OF COMPARISON
2 Primary Measure of Performance
3 What is Believes
4 Goal on Maintenance
5 Operators Involvement on Mtce
6 On Continuous Improvement
7 RCM and TPM Initial Approach
8 Plant Involvement
9 Focus on Maintenance
10 Applicability on Industries
11 Flexibility of combining the two
12 What it wants to Achieve
Overall Tabulation Result
YOUR SCORESHEET
Rolly Angeles
TPM vs RCM METHODOLOGY
Inspired by Change . . . RSA 2011
How To Score this Bout
• 3 knockdown rule is not in effect
• Only referee can stop the fight
• Judges to use the 10 point must
system
• There will be no standing 8 count
• Judge to score 10 points for the winner
of the round and 9 points for the loser
• In case of knockdown, opponent to wait
at a neutral corner, and judge to score
10 points for the winner and 8 for the
loser of the round
• In case of a knockdown, the fighter
cannot be saved by the bell in any round
Rolly Angeles
TPM vs RCM METHODOLOGY
Inspired by Change . . . RSA 2011
TALE OF THE TAPE
Seiiji Nakajima Father of TPM
John Moubray Develop RCM for Industries
Height : Smaller than Moubray Height : Taller than Nakajima
Weight : Lighter than Moubray Weight : Heavier than Nakajima
Age : Older than Moubray Age : Younger than Nakajima
12 rounds for the Undisputed Heavyweight Reliability and
Maintenance Improvement Championship of the World
RED CORNER BLUE CORNER
Rolly Angeles
TPM vs RCM METHODOLOGY
Inspired by Change . . . RSA 2011
How It is being Approached
• Without management commitment it is very
difficult for TPM to succeed. On the other hand,
RCM is much easier to implement than TPM.
This makes it easier for RCM to be implemented
than TPM.
With regards to approach RCM have an
edge on TPM.
• One of main difference in approach regarding
these two improvement initiatives is that TPM
is always a Top-down approach and a plant
wide improvement initiative while RCM can be
done from on a bottom-up approach.
RCM TPM
10 points 9 points
I give this round to RCM.
Rolly Angeles
TPM vs RCM METHODOLOGY
Inspired by Change . . . RSA 2011
• If the equipment Availability is 100%, is the equipment said to be
at its peak and reliable ? Answer : NO, The equipment may be 100% AVAILABLE but have a low
UTILIZATION or have not been utilized at all, hence utilization is not a
measure of reliability but only when the machine is used
• If the equipment Availability & Utilization is 100%,
is the equipment said to be at its peak & reliable ?
Answer : NO, The equipment may be 100%
utilized and available but the machine may
suffer from errors and speed loss. Example
a machine speed may be reduced so as not
to deliver problems in quality.
• If the equipment OEE is 90%, is the equipment said to be reliabile?
Answer : NOT EXACTLY, OEE is not about achieving 85% or more but
about satisfying the 3 components, in the case below the equipment is
suffering from a large rate of defects.
OEE = 100% (Utilization) x 97% (Efficiency) x 93% (Yield) = 90.21%
Primary Measure of Performance 2
No Reason for celebration
Rolly Angeles
TPM vs RCM METHODOLOGY
Inspired by Change . . . RSA 2011
• There is often a tendency to focus too heavily on primary functions when
assessing maintenance effectiveness. This is a mistake because in prac-
tice trivial secondary functions often embody bigger threats to the orga-
nization if they fail than primary functions.
As a result, every function must be consi-
dered when setting up the maintenance
effectiveness measures and targets
From page 302 of the book Reliability-Centred Maintenance by John Moubray
• The OEE as defined above only relates to
the primary function of any asset. This is
misleading because as in the case of the
gasoline storage system, every asset,
machine tools included have many more
functions than the primary function and
each of these functions have their own unique performance standards,
consequently OEE is not a measure of the overall effectiveness at all but
only a measure of the effectiveness with w/c the primary function of the
asset is being fulfilled. . . .
From page 304 Reliability-Centred Maintenance by John Moubray
Primary Measure of Performance 2
Rolly Angeles
TPM vs RCM METHODOLOGY
Inspired by Change . . . RSA 2011
The main indices used to measure TPM performance is Overall Equipment
Effectiveness. OEE is computed by multiplying its three components which
are Availability, Performance Rate and Quality Rate. OEE addresses the 6
major equipment losses encountered on the equipment which includes
breakdowns, set-up and conversion, start-up losses, idling and minor
stoppages, design speed loss, defect and rework losses.
For RCM, the main measure of perfor-
mance used is MTBF which is mostly
related to breakdowns and equipment
failures. Although OEE is not a perfect
measurement as explained in pages 91
to 92 of my book on WCM, the scope
of OEE is much larger than MTBF since
MTBF only covers one part of the equip-
ment losses which is breakdown, while
OEE covers the 6 major equipment
losses.
Primary Measure of Performance 2
Rolly Angeles
TPM vs RCM METHODOLOGY
Inspired by Change . . . RSA 2011
Having a high OEE does not gua-
rantee that the equipment is in-
deed reliable. Since OEE is only
focused on the primary function
of the equipment. Meaning as
long as output is high, quality is
good and the equipment is uti-
lized then OEE will be high. But
every equipment has both its
primary and secondary functions
and OEE is only focused on the
primary function of the equipment. But comparing these two primary
measurements, OEE is still wider in
scope than MTBF, since failures and
breakdowns are just a subset of OEE.
RCM TPM
9 points 10 points A flurry of punches by TPM and RCM
is hurt.
Primary Measure of Performance 2
I give this round to TPM.
Rolly Angeles
TPM vs RCM METHODOLOGY
Inspired by Change . . . RSA 2011
What it Believes 3
RCM TPM
10 points 9 points
TPM believes that in order to advance to any improvement
initiative, basic equipment condition must be carried out first.
On the other hand, RCM states that
the first step is to change the way
people think and apply this change
Thoughts to their asset. RCM has
a valid point because even before
basic equipment condition should
be established both operators and
maintenance should change the
way they think about their equip-
ment and build this new way of
thinking as part of their culture.
A cracking left and right to the jaw by
RCM. RCM wins this round.
Rolly Angeles
TPM vs RCM METHODOLOGY
Inspired by Change . . . RSA 2011
Goal on Maintenance
TPM goal is to zero out unplanned
breakdowns, while RCM goal is not
about eliminating breakdown but
understanding that each failure has
its own unique set of consequences
and if the consequences of the failure
is not acceptable then all effort must
be exhausted in order to reduce its
likelihood.
4
TPM goal is somewhat idealistic. In reality
what TPM is actually doing is not actually
eliminating breakdown but increasing the
MTBF of the equipment by adhering to the
basic equipment condition and lengthe-
ning the life of parts with inherent design
weaknesses
Rolly Angeles
TPM vs RCM METHODOLOGY
Inspired by Change . . . RSA 2011
RCM TPM
10 points 9 points
Maintenance is not about zeroing
out or eliminating failures but simply
trying to understand that it is more
important to understand the conse-
quences of failure rather than elimi-
nating the failure completely. In
reality, it is impossible to zero out
breakdowns.
A left hook and uppercut and TPM
is stunned.
Goal on Maintenance 4
What maintenance can do is simply
to anticipate, prevent, predict, con-
trol or prolong the duration of failure.
RCM explanation here is much com-
prehensive than TPM.
I give this round to RCM.
Department A = 10 BDO for April 2011
Department B = 1 BDO for April 2011
Which is the better department ?
In Dept. B what failed was the substation!
Rolly Angeles
TPM vs RCM METHODOLOGY
Inspired by Change . . . RSA 2011
Operators Involvement on Maintenance
Both RCM and TPM believes that operators
should be involved in maintenance. In any
RCM analysis, operators must be part of the
team doing the analysis since RCM believes
that it is the operators and not maintenance
that have direct contact and have witnessed
the failure.
One of the pillars of TPM is Autonomous
Maintenance which is done through a
detailed and structured 7 steps approach.
Maintenance teaches operators about
their own quipment and operators learn
not only to operate but also to take good
care of its equipment by understanding
what to clean, inspect and lubricate.
5
Rolly Angeles
TPM vs RCM METHODOLOGY
Inspired by Change . . . RSA 2011
RCM TPM
9 points 10 points
Operators Involvement on Maintenance
Autonomous Maintenance pillar let
operators understand that they, too,
have a role in maintaining their own
equipment by performing the basics
such as cleaning, lubrication and
checking for loose and incomplete
bolts on their equipment. In short,
the role of operators role is much
more detailed and structured in TPM
than RCM.
5
Left, right to the jaw, TPM connects,
RCM is staggered. I definitely give
this round to TPM.
Rolly Angeles
TPM vs RCM METHODOLOGY
Inspired by Change . . . RSA 2011
Its Belief on Continuous Improvement
On the other hand RCM focuses its
strength on adopting a robust and
structured approach about the correct
way to maintain the equipment by
assigning a tasks on all possible failure
modes that can affect the equipment
and adopting the most feasible mainte-
nance tasks to use with the aid of a
decision diagram or an algorithm.
This round is where TPM and RCM
have some forms of different point
of view. TPM is heavy on improve-
ments. TPM believes that the
equipment should be continuously
improved,
6
Rolly Angeles
TPM vs RCM METHODOLOGY
Inspired by Change . . . RSA 2011
There is a thin line between improving the equipment and maintaining
the equipment. There are times that we improve or modify the equipment
only to learn that the equipment will be decommissioned because of
obsolescence. Most improvements take time to accomplish. Some may
even take several months, hence a person who is on duty today has to
maintain the equipment as it exists today and not what it should be there
in the future.
Before considering improving or modifying the
equipment, have we asked ourselves if the asset
is here to stay for a long time or will it be deco-
mmissioned. Hence, before trying to improve or
redesign the equipment we must have a concrete
answer to these questions.
Its Belief About Continuous Improvement
I believe this round belongs to
RCM.
RCM TPM
10 points 9 points
6
I give RCM this round.
Rolly Angeles
TPM vs RCM METHODOLOGY
Inspired by Change . . . RSA 2011
RCM and TPM Initial Approach
RCM TPM
9 points 10 points
7 RCM starts by determining the asset
functions and failure modes, while
TPM believes in addressing equip-
ment basic condition first. Many
failures start with small things and
it is from these small things which
are often left neglected that cause
big problem.
Big problems are just an accumulation
of small problems. TPM believes that big
failures can be prevented if we address
the basics. In fact some of the failure
modes can be reduced if basic equipment
condition is well established on the asset
A flurry of punches and RCM is down on
the ropes. I give TPM credit for this round.
Rolly Angeles
TPM vs RCM METHODOLOGY
Inspired by Change . . . RSA 2011
Plant Involvement
RCM TPM
9 points 10 points
TPM will involve everyone from the organiza-
tion, from the Top down to the shopfloor.
Each will have their own TPM pillar to be
busy about. Even people from offices will
be involved in Office/Admin TPM.
On the contrary, RCM involvement would be
limited to maintenance, operators with the
most extensive knowledge on their assets,
and from time to time vendors mostly who
have direct impact on the equipment being
analyzed. I doubt if HRD or the finance
department can be involved directly in an
RCM analysis.
Again, as for plant involvement, I give this round to TPM. At this point of
the round both RCM and TPM are dead even with a score of 76 points.
Wicked left hook by TPM, RCM is staggered and the crowd is wild on its
feet.
RCM is like an Elite Delta Force
TPM is for everyone while RCM Is not
8
TPM wins this round.
Rolly Angeles
TPM vs RCM METHODOLOGY
Inspired by Change . . . RSA 2011
Focus on Maintenance
RCM TPM
10 points 10 points
9 TPM focuses on addressing the six big equipment losses. By reducing
these equipment losses OEE will improve. On the other hand RCM focuses
on both primary and secondary functions of the equipment.
RCM highlights the importance of secondary functions of the equipment.
It allows us to understand that there are cases where failure of secondary
functions poses a bigger treat rather than the failure of the primary function.
I think both RCM and TPM have good points
on this. Both fighters standing toe to toe,
no one is backing out. . This round is a draw
Rolly Angeles
TPM vs RCM METHODOLOGY
Inspired by Change . . . RSA 2011
Applicability on Industry
RCM TPM
10 points 9 points
10 Speaking about its applicability to industries, RCM has an edge on this
as its process can be applied and can suit mostly any type of industry
from the nuclear, oil and gas, mining, metals, manufacturing, power plants,
assembly plants, airline industry, where it originated, shipping, automo-
tive, as long as there are equipment and assets to be maintain.
TPM application is mostly suited for
manufacturing industries. I just won’t
recommend TPM to be used for the
oil and gas sector or the airline
industries unless we have a way of
measuring the bad molecules on oil
so that OEE can be calculated. TPM
is a good improvement strategy, but
it is not fit for use for these industries.
Hence, for industry application, I think
RCM is more diversified to use than
TPM. I’ll give this round to RCM.
Can you perform initial cleaning here !
Rolly Angeles
TPM vs RCM METHODOLOGY
Inspired by Change . . . RSA 2011
RCM TPM
9 points 10 points TPM wins this round
If we buy a pizza, TPM itself is the whole
pizza, while RCM is just a of the pizza. I
see RCM fit perfectly into the higher
phases of Planned Maintenance which
is one of the major pillars of TPM.
In fact, several TPM case studies include
doing RCM on its equipment through the
higher phases of Planned Maintenance.
In view of this, TPM is more flexible than
RCM.
There is no mention of alignment to other improvement initiatives in the
report by Stanley Nowlan and Howard Heap nor from the book by Moubray
on RCM. RCM also provides a standard SAE JA1011 to differentiate its
RCM from other streamlined versions.
11 Flexibility of Combining TPM and RCM
Rolly Angeles
TPM vs RCM METHODOLOGY
Inspired by Change . . . RSA 2011
What it wants to Achieve in Maintenance 12 TPM will aim for Maintenance Prevention while RCM goes for Proactive
Maintenance. TPM is more idealistic, since in reality, we really cannot
eliminate maintenance. Our equipment is not a plug and play asset where
we expect it to be reliable all the time. TPM wants us to think about an
ideal plant with zero breakdown, accidents and defect, and what it takes
for us to bring our plant closer and closer to it.
An ideal plant has been chosen by TPM
so that its people will aim to continuous-
ly improve. TPM does not want us to re-
main in the same, but to improve gra-
dually step by step, drip by drip.
People believe that TPM is a continuous
journey, and if they have one word that
is out of their vocabulary, it is the word
best, because TPM believes that the
best can still be made better.
Rolly Angeles
TPM vs RCM METHODOLOGY
Inspired by Change . . . RSA 2011
12 On the contrary, RCM aims for being Proactive,
finding the most suitable maintenance tasks for
each failure mode uncovered, doing RCM increa-
ses the assets integrity by considering both en-
vironmental and safety implications before con-
sidering its effects on operations.
RCM believes that maintenance is about under-
standing the consequences of failure rather
than eliminating the failure itself. Both RCM
and TPM clearly explain what they want to
achieve in maintenance and that the key to
all this will be their people. If people change,
the culture will change and their assets will
be improved.
With less than a minute left in the bout, both fighters give it all. Both
fighters in the middle of the ring toe to toe, hitting each other with every-
thing they got, a bridge to the nose and the bell ends, the crowd wild on
its feet, probably one of the best match ever. This round is a draw !
What it wants to Achieve in Maintenance
Rolly Angeles
TPM vs RCM METHODOLOGY
Inspired by Change . . . RSA 2011
TPM vs RCM SURVEY QUESTION
• Which do you think have an edge RCM or TPM ?
Write the letter in a 1/8 piece of paper, and submit to the facilitator.
The result of the survey will be sum up and given as a percentage
of the class. Answer as honest as you can.
A) I think RCM have definitely have an edge
over TPM. RCM wins this bout.
B) I think TPM have definitely an edge
over RCM. TPM wins this bout
C) I think neither one have an edge since
both of them are not contradictory. This
bout is a draw
D) I do not know which one has an edge, I am
just here to listen. No comment on the bout
Answer honestly which letter do you think that
best fits your situation
Rolly Angeles
TPM vs RCM METHODOLOGY
Inspired by Change . . . RSA 2011
1 How it is being approached 10 9 RCM wins
ROUND RCM TPM RESULTS POINT OF COMPARISON
2 Primary Measure of Performance 9 10 TPM wins
3 What is Believes 10 9 RCM wins
4 Goal on Maintenance 10 9 RCM wins
5 Operators Involvement on Mtce 9 10 TPM wins
6 On Continuous Improvement 10 9 RCM wins
7 RCM and TPM Initial Approach 9 10 TPM wins
8 Plant Involvement 9 10 TPM wins
9 Focus on Maintenance 10 10 Draw
10 Applicability on Industries 10 9 RCM wins
11 Flexibility of combining the two 9 10 TPM wins
12 What it wants to Achieve 10 10 Draw
Overall Tabulation Result 115 115 Draw
Rolly Angeles
TPM vs RCM METHODOLOGY
Inspired by Change . . . RSA 2011
TPM and RCM may have different origins but these two heavyweight
maintenance methodology are not contradicting but rather they are
complementary. It is the individual consultants that do the contra-
diction and not the methodologies
Is TPM and RCM Contradictory or Complementary ?
Rolly Angeles
TPM vs RCM METHODOLOGY
Inspired by Change . . . RSA 2011
I would like to express my thanks
to you for taking time to view this
brief presentation on TPM vs RCM
(Thank You)
Website : http://www.rsareliability.com
Email : [email protected]
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