INFORME TPM

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TALLER Y MANTENIMIENTO MANTENIMIENTO PRODUCTIVO TOTAL

TPM

CARLOS FARLEY ZAMUDIO MELO COD. 201521072

DOCENTE

ING. NELSON HUMBERTO CASTRO RUIZ

CORPORACIÓN CORPORACIÓN UNIVERSITARIA UNINAVARRA INGENIERIA INDUSTRIAL VI SEM. NEIVA - HUILA 2018-02

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CONTENIDO 1. INTRODUCCIÓN................................................................................................................3 2. ANTECEDENTES................................................................................ ...............................5 3. ¿QUÉ ES TPM?....................................................................................................................7 4. LAS 6 GRANDES PÉRDIDAS............................................................................................9 5. CARACTERISTICAS........................................................................................................12 6. MÉTODOS..........................................................................................................................13 7. OBJETIVOS........................................................................................................................19 8. BENEFICIOS…………......................................................................................................20 9. TPM COMO SISTEMA……………...………….............................................................22 10. PRINCIPIOS FUNDAMENTALES...……….….................. ............................................24 11. ACTIVIDADES FUNDAMENTALES……….................................................................25 12. IMPLANTACIÓN DE TPM EN UNA EMPRESA..........................................................27 13. PLAN MAESTRO TPM……………………………........................................................34 14. LAS 5´S…………………………………………….........................................................36 15. PILARES DEL TPM..........................................................................................................39 16. DOCE (12) PASOS PARA IMPELMENTAR EL TPM...................................................48 17. MEDIDORES......................................................................................................................57 18. FORMATOS.......................................................................................................................59 19. EMPRESAS QUE IMPLEMENTAN TPM.......................................................................64 20. CONCLUSIÓN...................................................................................................................68

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1. INTRODUCCIÓN Mantener las instalaciones automatizadas en óptimas condiciones de utilización no solo mejora la productividad de las máquinas, es también la garantía de un flujo continuo de  producción.  producción. Para ello ello gestionar gestionar eficientement eficientementee el mantenimien mantenimiento to es fundamental. fundamental. El TPM (Mantenimiento Productivo Total) es la metodología clave para conseguirlo. Contenido 

TPM: origen y contexto



Las 6 perdidas crónicas de las instalaciones



Las 5S: cimientos del TPM



TPM. Modelo de 8 Pilares

La filosofía del TPM TPM es una filosofía de mantenimiento cuyo objetivo es eliminar las pérdidas en  producción debidas al estado de los equipos, o en otras palabras, mantener los equipos en disposición para producir a su capacidad máxima productos de la calidad esperada, sin  paradas no programadas. Esto Es to supone: 

Cero averías



Cero tiempos muertos



Cero defectos achacables a un mal estado de los equipos

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Se entiende entonces perfectamente el nombre: mantenimiento productivo total, o mantenimiento que aporta una productividad máxima o total.

MISION DEL TPM Es lograr que la empresa obtenga un rendimiento económico creciente en un ambiente agradable como producto de la interacción del personal con los sistemas, equipos y herramientas

Objetivos específicos: 

Cero averías en los equipos.



Cero defectos en la producción.



Cero accidentes laborales.



Mejorar la producción.



Minimizar los costes.

Medios de mejorar del mantenimiento 

Averías



Repuestos



Manos de obras

ACTIVOS DEL TPM 

Personas

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2. ANTECEDENTES El origen del término “Mantenimiento Productivo Total” (TPM) se ha discutido en

diversos escenarios. Mientras algunos afirman que fue iniciado por los manufactureros americanos hace más de cuarenta años, otros lo asocian al plan que se usaba en la planta  Nippodenso, una manufacturera de partes eléctricas automotrices de Japón a fines de la década de los 60. Seiichi Nakajima, un alto funcionario del Instituto Japonés de Mantenimiento de la Planta (JIPM), recibe el crédito de haber definido los conceptos de TPM y de ver por su implementación en cientos de plantas en Japón. Después de la segunda guerra mundial, las industrias japonesas llegaron a la conclusión de que para competir con éxito en el mercado mundial tenían que mejorar la calidad de sus  productos. Con este fin, incorporaron técnicas de gestión y fabricación procedentes de los Estados Unidos y las adaptaron a sus particulares circunstancias. Posteriormente, sus  productos llegaron a conocerse a través de todo el mundo por su calidad superior, concentrando la atención del mundo en el estilo japonés de técnicas de gestión. El mantenimiento preventivo se introdujo en los años cincuenta y el mantenimiento  productivo alcanzó un buen grado de implantación en los años sesenta. El desarrollo del TPM comenzó en los años setenta. El tiempo que precede a los años cincuenta puede denominarse período de “mantenimiento de averías”. El Dr. Deming inició sus trabajos en Japón a poco de terminar la 2a. Guerra Mundial. Como experto en estadística, Deming comenzó por mostrar a los Japoneses cómo podían

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de trabajo propia del pueblo japonés, se creó toda una cultura de la calidad, una nueva forma de vivir. De ahí surgió TQM, "Total Quality Management" un nuevo estilo de manejar la industria. Cuando nos referimos al TPM, se trata en realidad de mantenimiento productivo de estilo americano, modificado e intensificado para adaptarlo al entorno industrial japonés. El mantenimiento productivo reconoce la importancia de la fiabilidad, mantenimiento y eficiencia económica en el diseño de la planta, pero aplica la división del trabajo entre el  personal de mantenimiento y producción. El departamento de mantenimiento es el encargado de las reparaciones y entregar el equipo al departamento de producción para que cumpla con su función exclusiva de producir. Contrariamente, muchas corporaciones  japonesas han modificado el mantenimiento productivo americano de forma que todos los empleados pueden participar. En Japón, el TPM ha sido generalmente aceptado desde su introducción. Por ejemplo, constituye un soporte esencial del sistema de producción Toyota. El TPM ha sido igualmente implantado por muchas de las filiales de Toyota. De acuerdo con su creador, Taiichi Ohno, el sistema de producción Toyota está basado en la eliminación absoluta del despilfarro. En la producción “justo a tiempo” de Toyota, solamente se producen los

elementos necesarios. En otras palabras el sistema de producción es un esfuerzo para lograr los defectos cero y niveles de inventarios cero.

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3. ¿QUÉ ES EL TPM? Mantenimiento Productivo Total es la traducción de TPM (Total Productive Maintenance). El TPM es el sistema japonés de mantenimiento industrial desarrollado a partir del concepto de "mantenimiento preventivo" creado en la industria de los Estados Unidos (1). El Mantenimiento Productivo Total (TPM) es un sistema de gestión que evita todo tipo de  pérdidas durante la vida entera del sistema de producción, maximizando su eficacia e involucrando a todos los departamentos y a todo el personal desde operadores hasta la alta dirección, y orientando sus acciones apoyándose en las actividades en pequeños grupos. En la fábrica ideal, la maquinaria debe operar al 100% de su capacidad el 100% del tiempo. El TPM es un poderoso concepto que nos conduce cerca del ideal sin averías, defectos ni  problemas de seguridad. El TPM amplía la base de conocimientos de los operarios y del  personal de mantenimiento y los une como un equipo cooperativo para optimizar las actividades de operación y mantenimiento. La innovación principal del TPM radica en que los operadores se hacen cargo del mantenimiento básico de su propio equipo. Mantienen sus máquinas en buen estado de

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El TPM es una nueva dirección para la producción. El TPM, que organiza a todos los empleados desde la alta dirección hasta los trabajadores de la línea de producción, es un sistema de mantenimiento del equipo a nivel de compañía que puede apoyar las instalaciones de producción más sofisticadas.

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4. LAS SEIS GRANDES PÉRDIDAS

Desde la filosofía del TPM se considera que una máquina parada para efectuar un cambio, una máquina averiada, una máquina que no trabaja al 100% de su capacidad o que fabrica  productos defectuosos de fectuosos está es tá en una situación situa ción intolerable que produce pr oduce pérdidas pér didas a la empresa.

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ejemplo, al inicio en la mañana, al cambiar de lugar de trabajo, al cambiar una matriz o matriz, o al hacer un ajuste.

3. Pérdidas por paros menores,  Marchas en vacío, esperas y detenciones menores (averías menores) durante la operación normal que producen pérdidas de tiempo, ya sea por problemas en la instrumentación, pequeñas obstrucciones, etc.

4. Pérdidas de Velocidad de operación; velocidad reducida (el equipo no funciona a su capacidad máxima), que produce pérdidas productivas al no obtenerse la velocidad de diseño del proceso.

5. Pérdidas de defectos de calidad y retrabados;  Defectos en el proceso, que  producen pérdidas productivas al tener que rehacer partes de él, reprocesar  productos defectuosos o completar actividades no terminadas.

6. Pérdidas de tiempo;(rendimiento) propias de la puesta en marcha de un proceso nuevo, marcha en vacío, periodo de prueba, etc. El análisis cuidadoso de cada una de estas causas de baja productividad lleva a encontrar las soluciones para eliminarlas y los medios para implementar estas últimas. Es fundamental que el análisis sea hecho en conjunto por el personal de producción y el de mantenimiento, porque los problemas que causan la baja productividad son de ambos tipos

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

Avería transitoria. Afecta durante un tiempo limitado al elemento y adquiere nuevamente su actitud para realizar la función requerida, sin haber sido objeto de ninguna acción de mantenimiento.

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12

5. CARACTERÍSTICAS Las características del TPM más significativas son: 

Acciones de mantenimiento en todas las etapas del ciclo de vida del equipo. Participación amplia de todas las personas de la organización.



Es observado como una estrategia global de empresa, en lugar de un sistema para mantener equipos.



Orientado a la mejora de la Efectividad Global de las operaciones, en lugar de prestar atención a mantener los equipos funcionando.



Intervención significativa del personal involucrado en la operación y producción en el cuidado y conservación de los equipos y recursos físicos.



Procesos de mantenimiento fundamentados en la utilización profunda del conocimiento que el personal posee sobre los procesos.

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13

6. MÉTODOS Enfoque La metodología de mantenimiento para el análisis y eliminación de averías se orienta a los siguientes puntos:

Comprender y conocer el equipo profundamente. En los últimos años se ha venido insistiendo que las empresas que pretendan mantenerse competitivas en los mercados del futuro, deberán preocuparse por mejorar el conocimiento de todo el personal y garantizar que existe un proceso de adquisición y transferencia efectiva de experiencias o conocimiento entre todos los trabajadores. Este es el punto de partida del TPM, ya que busca crear una organización empresarial en continuo aprendizaje y de mejora del conocimiento del personal técnico y operativo.

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14

Reflexión sobre los fenómenos. Los fenómenos son considerados cuidadosamente y en forma lógica. Se emplea un tiempo  para realizar la reflexión sobre los fenómenos identificados identificados y en lo posible, se verifica la hipótesis directamente sobre cada uno de los componentes de la máquina que se estudia. Se  pretende evitar que el grupo humano tome decisiones decisiones con la única información información tomada a  partir de una tormenta de ideas. Este tipo de metodología permite adquirir conocimiento, conocimiento, no solo para la eliminación de los factores causales, sino que permite preparar al equipo para realizar aportes innovadores de cambio de diseño y modificaciones que permitan mejorar el rendimiento de la máquina.

Priorizar la información con cuidado y método El experto japonés Shirose manifiesta que la priorización es necesaria para estudiar en forma ordenada una situación. Sin embargo, debido a una priorización realizada con poco

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

Análisis Modal de Fallos y Efectos (AMFE)

La estrategia de Mantenimiento Productivo Total para el diagnóstico de averías se inicia con la utilización de la técnica Porqué-Porqué. Esta técnica permite reducir en forma dramática la repetición de las averías, pero no la elimina en forma definitiva. Por este motivo es necesario emplear a continuación el método PM para lograr eliminar de raíz la mayor cantidad de factores causales y alcanzar altos niveles de confiabilidad en los equipos.

Cuando un equipo se encuentra bien mantenido y presenta una avería, se puede realizar su diagnóstico aplicando un análisis PM. Pero si el equipo se encuentra deteriorado y sus condiciones básicas están descuidadas, se considera que es más apropiado iniciar un estudio con la técnica Porqué-Porqué, antes de aplicar un análisis PM.

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Diagnóstico en equipos avanzados o complejos Cuando se trata de equipos nuevos, complejos o donde el deterioro acumulado es mínimo, se recomienda emplear directamente el método PM. En algunas empresas japonesas emplean de forma sistemática la combinación de AMFE y método PM para eliminar problemas del equipo que afectan la calidad del producto (Mantenimiento de Calidad). Este diagnóstico  puede llegar a ser sofisticado sofisticado y lo realizan especialmente especialmente los ingenieros ingenieros de proceso y mantenimiento.

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Paso 2. Observación En este segundo paso se comprende la forma como se presentó la avería y las condiciones del medio presentes en el momento de la avería. Un buen juicio ayudará a descartar factores causales. Para este fin se puede tomar información cualitativa empleando un diagrama de afinidad y posteriormente priorizar sus títulos haciendo uso de un diagrama de relaciones.

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Paso 6. Verificación Se observa el comportamiento de los equipos intervenidos con el objeto de evaluar la efectividad de la acción. Se emplea un tablero MTBF u otro tablero de control visual para realizar el seguimiento de las acciones correctivas introducidas.

Paso 7. Estandarización Las acciones correctivas se deben estandarizar para asegurar que la avería no se repetirá

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7. OBJETIVOS El proceso TPM ayuda a construir capacidades competitivas desde las operaciones de la empresa gracias a su contribución a la mejora de la efectividad de los sistemas productivos, flexibilidad y capacidad de respuesta, reducción de costes operativos y conservación del “conocimiento” industrial.

El TPM tiene como propósito en las acciones cotidianas que los equipos operen sin averías

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8. BENEFICIOS

El TPM permite diferenciar una organización en relación a su competencia debido al impacto en la reducción de los costes, mejora de los tiempos de respuesta, fiabilidad de suministros, el conocimiento que poseen las personas y la calidad de los productos y servicios finales.

a. Beneficios con respecto a la organización 

Mejora de calidad del ambiente de trabajo.

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c. Beneficios con respecto a la productividad 

Elimina pérdidas que afectan la productividad de las plantas.



Mejora de la fiabilidad y disponibilidad de los equipos.



Reducción de los costes de mantenimiento.



Mejora de la calidad del producto final.



Menor coste financiero por recambios.



Mejora de la tecnología de la empresa.

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9. TPM COMO SISTEMA El siguiente modelo TPM debe servir para diseñar una estrategia de implantación. El TPM

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Estrategia y Dirección por Políticas Misión, visión y valores de la compañía Objetivos estratégico de las operaciones Despliegue de objetivos y acciones Gestión orientada al proceso

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10. PRINCIPIOS FUNDAMENTALES FUNDAMENTALES 

Participación de todo el personal, desde la alta dirección hasta los operarios de

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11. ACTIVIDADES FUNDAMENTALES

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funcionamiento que puedan producirse como consecuencia de fallos de concepción, diseño, desarrollo y construcción del equipo, instalación y pruebas del mismo hasta que se consiga el establecimiento de su operación normal con producción regular. El objetivo es lograr un

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19. EMPRESAS QUE IMPLEMENTAN TPM

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20. CONCLUSIÓN El TPM se orienta a crear un sistema corporativo que maximiza la eficiencia de todo el sistema productivo, estableciendo las operaciones de la empresa. Esto incluye “cero accidentes, cero defectos y cero fallos” en todo el ciclo de vida del sistema productivo. Se aplica en todos los sectores, incluyendo producción desarrollo y departamentos administrativos. Se apoya en la participación de todos los integrantes de la empresa, desde la alta dirección hasta los niveles operativos. La obtención de cero perdidas se logra a través del trabajo de  pequeños equipos. 

Elimina perdidas que afectan la productividad.



Mejora la confiablidad y disponibilidad de los equipos.



Reduce los costos de mantenimiento y producción.



Mejora la calidad del producto final.



Aumenta el ciclo de vida de los equipos.



Aumenta la capacidad de respuesta.



Desarrolla nuevas competencias técnicas.

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

Obtención de cero accidentes.



Inversión de los porcentajes de mantenimiento a 80% programado y 20% correctivo.



Creación de cultura responsabilidad, disciplina y respeto por las normas.



Mejora las condiciones ambientales.



Elimina radicalmente las fuentes de contaminación.



Mejor control de las operaciones.

Para recordar los pasos esenciales 

Limpieza inicial, quitar el polvo y los contaminantes del equipo.



Eliminar las fuentes de contaminación y las piezas inaccesibles.



 Normas de limpieza y lubricación, establecer normas claras y fáciles de mantener.



Inspección general, enseñar las destrezas para realizar una inspección.



Inspección autónoma, desarrollar y utilizar hojas de chequeo del mantenimiento.



Gestión y control del lugar de trabajo, estandarizar las normas a cumplir.



Implementación completa del mantenimiento autónomo.

Tener en cuenta las condiciones que perjudican la obtención del rendimiento de una

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70

e) Mejorar las funciones operativas y de mantenimiento, buscando prevenir errores humanos.

Por otra parte es posible definir 5 medidas básicas para eliminar las fallas: 

Satisfacer las condiciones básicas del equipo.



Respetar las condiciones de utilización específicas en el manual de operación.



Remediar las causas de degradación del equipo tomando medidas a tiempo para evitarlo.



Corregir u optimizar las deficiencias de concepción y/o diseño.



Mejorar las funciones operativas y de mantenimiento, buscando prevenir errores humanos.

5 aspectos claves para lograr un ambiente de calidad en el trabajo 

Organización



Limpieza



Ordenamiento



Superación



Personal

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¿Cuándo debe implementarse TPM? Debe utilizarse cuando los requerimientos de a organización sean los de tener plantas, equipos e instalaciones de todo tipo, confiables, continuas y seguras. ¿Que lo hace exitoso? Hay que tener en cuenta que gran parte del éxito en su implementación depende de la cultura generada en las personas. 

Foco claro



Alto compromiso (vertical y horizontal)



Evaluación de avance por etapas



Seguimiento a las perdidas



Definición de indicadores de desempeño



Uso rigurosa de la metodología



Planeación adecuada

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21. BIBLIOGRAFÍA http://www.biblioteca.udep.edu.pe/Bib http://www.bib lioteca.udep.edu.pe/BibVirUDEP/tesis/ VirUDEP/tesis/pdf/1_44_176_10 pdf/1_44_176_10_295.pdf  _295.pdf 

http://bibing.us.es/proyectos/abreproy/4952/fichero/PFCJuanCarlosAlvarez.pdf  http://www.ceroaverias.com/ https://sites.google.com/site/apalacioposada/mantenimiento-autonomo---paso-1-limpiezainicial http://copimerainternacional.org/inicio/images/conferencias/tpmIberoamerica.pdf  http://www.euskalit.net/gestion/?p=855 http://ww1.areatpm.com/caf/?ses=Y3JlPTE1MjI5NTE1MzQmdGNpZD13dzEuYXJlYXR  wbS5jb201YWM2NjU2ZGQ1ZWNjMi45MDY5Mzk1NiZma2k9MCZ0YXNrPXNlYXJja CZkb21haW49YXJlYXRwbS5jb20mbGFuZ3VhZ2U9ZXMmYV9pZD0zJnNlc3Npb249N 3dRd2ZFYWlEWEVBMDBDODlQaGw=&query=Formatos%20Mantenimiento&afdToke n=3B1ggFm2WbXJ3hsR0fXXvjjtprt4l7EDrIikJmhPfcQ5qPH3TKctO5id5xl7L7mK6GXvl KEJP6i3n6gOiat2Y26CxnJSMr3cAZE5zLCEUG8 http://dmros.com.ar/sitio/download/tpm.pdf