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GLOSSARY - A Guide to TPR Terms
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U |
V |
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X |
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5Ss- Sort, Set in Order, Shine, Standardize, Sustain- The basics which support visual controls, standard operations, and other just-in-time concepts. The development of organizational orderliness in the workplace.
- A -
Acceptable Condition
- That condition established for a particular use and not less than what is stipulated by statutory or compliance requirements; meeting a functional standard for equipment operation.
Adjustment
- Minor tune-up activities requiring simple hand tools, no parts, and usually lasting no more than 30 minutes in duration.
Assets
- The physical resources of the organization which would include plants, facilities, fleets and their parts and components.
Asset List - A
register of the organization’s physical resources with information on manufacturer,
vendor, specifications, classification, warranty, costs, and table status.
Asset Management
- The process and systematic planning and control of a particular physical resource throughout its Life Span or economic life.
Asset Number
- A unique alphanumerical identifier from the Asset List which is used to refer to a given asset.
Autonomous Maintenance
- Involvement of operators in maintenance activities.
Availability - The period of scheduled time for which an asset is capable of performing its designed function, stated as a percentage.
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- B -
Backlog - Work orders prioritized and planned waiting scheduling and carrying out. This is considered work identified but not yet done.
Benchmarking - The
study of outstanding practices…usually done through visits or benchmark data
comparisons.
Bill of Materials (BOM)- List of parts and components for a given asset, often structured in a cascading hierarchical manner starting with major components or assemblies down to minor parts.
Breakdown - Loss
of functional ability or major loss of quality output—fails to meet the functional
standard.
Breakdown Maintenance - A policy where no maintenance is conducted unless asset no longer meets functional standard (also see Run-To-Failure).
Breakthrough Project- A planned project that uses Zest Factors to achieve a tangible, bottom-line result in a short period of time.
Breakthrough Strategy - Strategy that enables organizations to tap into hidden reserves to produce major performance gains.
Breakthrough Team- Functional or cross-functional team working on a very specific and manageable goal for a period of 45-60 days.
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- C -
Centralized Zone - Often
in the form of “area” or “zone” maintenance where craftspeople are assigned to a designated location such as a department, a process line, or equipment grouping. These people report directly to maintenance supervision but often times are “dotted line” reporting
to production supervisors. Their shops or work areas are physically located
near the equipment they service.
Centralized- Under traditional centralized maintenance structure; craftspeople are sent out from shops or central locations. Decision-making tends to be hierarchical from management to supervisory to hourly ranks.
Champion - The change leader; provides systems and operational assistance.
Change Agent- An internal or external resource such as a consultant or full-time staff person, who is the facilitator of change - provides assistance and guidance to Sponsor and Champion; provides people and process support.
Change Out - The removal and replacement of a given part or component with a new or rebuilt one.
Chronic LossCLAIRE
- Cleaning, Lubricating, Adjusting,
Inspecting, Repairing, Eliminating – Operator-performed
basic care.
Clean
- The removal of dirt, debris, and contamination for the purpose of inspection and elimination of chronic problems.
CMMS
- Computerized Maintenance Management System.
Component
- A constituent part of an asset,
usually modular in design and replaceable which is serialized and interchangeable—this
could include assemblies.
Component Number
- An alphanumeric designation structured by the system or serial number assigned to the component.
Condition-based Monitoring (CBM)
- Maintenance activity based on measured condition of an asset
Corrective Maintenance (CM)
- Maintenance which is required when an item has failed or worn out, to bring it back to working or functional state. Corrective maintenance is carried out on all items where the consequences of failure or wearing out are not significant and the cost of corrective maintenance is not greater than preventive maintenance. Corrective maintenance may or may not be scheduled.
Countermeasure
- An improvement made to eliminate contamination or to improve access for inspection, lubrication, cleaning, etc.
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- D -
De-Centralized Zone- When the organization moves to a decentralized structure, decision-making is moved out of the maintenance department and into the location where the work is being performed such as operations or production. At this point, production personnel take on direct supervisory or management responsibilities of the crafts.
Defect- An abnormality or condition that causes deviation from design condition or expected performance.
Deferred Maintenance- Maintenance activity that can be or has been postponed from a schedule due to availability of funds, resources or parts.
Deterioration- The decline in performance moving to a possible loss of functionality or loss of quality standard.
Down- Asset out of service, usually due to a breakdown or loss of quality output, unacceptable condition or due to scheduling.
Downtime- Period of time in which an item or asset is not functional or scheduled outage.
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- E -
Early Equipment Management- Structured activities in the beginning of the life cycle to improve efficiency of equipment use and lower life-cycle cost.
EIT - Equipment Improvement Team- Teams structured to improve machine reliability and efficiency. EITs are typically made up of representatives from maintenance, operations, engineering, and the TPR Coordinator.
Emergency Maintenance (EM)- Maintenance requiring sudden and immediate corrective action for health, safety, environmental, or economic risks, caused by loss of functionality.
Equipment Repair History- A chronological list of defaults, repairs, replacements, and particular costs on assets in order that chronic and recurring problems can be identified and resolved as well as economic decisions such as buy-rebuild, etc. can be made.
Equipment Use- Accumulated hours, cycles of use, distance, that the equipment is working.
Estimated Replacement Value (ERV)- The highest price in terms of cash that would be required to replace a property with another of similar age, quality, origin, appearance, provenance and condition, within a reasonable length of time in an appropriate and relevant market; also known as the Fleet Replacement Value.
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- F -
Failure
- Termination of the ability of an item to perform its intended function to a set standard.
Failure Analysis
- The study of failures to analyze the root cause in order to develop appropriate improvements, countermeasures to mitigate or reduce the likelihood of recurrence (also see Root Cause Failure Analysis).
Failure Codes
- Identifying codes to index causes of failure in a quick and repetitive means such as failure codes on a work order such as bearing failure, lack of lubrication, operator abuse, etc.
FMEA
- Failure Mode and Effect Analysis – The
study of the modes and effects of failure.
Focus Teams
- Cross-functional teams working on improving systems or processes.
Forecasting
- Ability to project and schedule of impending maintenance activities.
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- G -
Gap Analysis- The study of existing performance compared to ideal performance.
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- I -
Implementation Team- Provides direct support for TPR implementation and reports to the Steering Council.
Inventory Control- Managing the acquisition, receipt, storing and issuance of parts and materials to maximize the investment efficiency of working assets.
Inventory Turns- Ratio of the amounts of disbursements compared to the value of the stores.
Issues- Stock consumed through stores.
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- J -
Job Aids- Documents or devices used to instruct or inform.
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- K -
Kitting- Pre-staging and pre-assigning parts in kits readied for a particular job.
KPI- Key Performance Indicators - High-level indicators or metrics/measures of performance.
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- L -
LAER
- Listen, Acknowledge, Explore, Respond - A four-part method for overcoming objections.
LCC
- Life Cycle Costs- Total cost of
a piece of equipment from “cradle to grave” (total
cost of life cycle of the equipment).
Labor Availability
- Percentage of the time the maintenance crew is free to perform productive work in a given scheduled period.
Labor Utilization
- Percentage of the time the maintenance crew is performing productive work in a given scheduled period.
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- M -
MP
- Maintenance Prevention - Principles applied to equipment design to make it as fail-safe and reliable as possible.
MTBF
- Mean Time Between Failures - Reliability measure calculated by dividing the number of failures into the operating time, and is usually stated in hours. See also Reliability.
MTTR
- Mean Time To Repair - Measures maintainability and is the average time to repair. It is calculated by dividing the total time to repair (including all delays) by the number of failures. See also Maintainability.
Maintainability
- The degree of ease that equipment
can be inspected, services, lubricated, repaired—often shown as Mean Time
To Repair (MTTR).
Management of Change (MOC)
- A formal process that examines the need and impact of change efforts; provides documentation of such change and provides a communication process to roll the change out.
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- O -
OEE- Overall Equipment Effectiveness - A measure used to determine how well a piece of equipment is truly operating by measuring availability x performance x quality.
OPE - Overall Plant (or Process) Effectiveness- Tool used to determine how the entire system is operating (much broader than OEE).
Overhaul- A comprehensive examination and restoration of an item to an acceptable and given standard.
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- P -
PdM Predictive Maintenance
- Use of measured engineering parameters
against known engineering limits for early detection, analyzing and correcting
equipment problems before a failure
occurs—may include oil analysis, thermal testing, ultra-sonic, etc.
PM
- Preventive Maintenance - Maintenance activities carried out at predetermined intervals such as cycles, mileage, or hours to reduce the likelihood of functional failure.
PPM
- Preventive & Predictive Maintenance
or Parts Per Million.
Pick List
- A list of parts and/or tools to be set-aside or kitted for an upcoming job.
Planned Maintenance
- Maintenance activities carried out according to a documented plan of tasks, skills, and resources.
Priority
- Relative importance of a single job or asset to other jobs or assets based on economic loss, safety threat, health or environmental risk, etc. in order to schedule jobs.
Proactive
- A style of initiative that is anticipatory and planned rather than reactive.
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- Q -
Quick-checks
- Visual cues that give us information or tell us when equipment is in or out of spec.
- RCFA
- Root Cause Failure Analysis – A
formal investigative process to discover the causes of a functional failure
or potential failure and to provide countermeasures
or improvements to prevent recurrence.
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- R -
Rebuild
- Restore an item to acceptable conditions or standards.
Red Tag
- Tag used to sort and eliminate unnecessary items from a particular work area.
Reliability
- Ability of an item to perform
a required or designed function under stated conditions for a stated period
of time—often tracked as Mean Time Between Failures.
See also MTBF.
Repair
- To restore an item to an acceptable or functional condition by replacement, renewal, or mending.
Running Maintenance
- Maintenance that can be safely performed while the equipment is running.
Run-To-Failure (RTF)
- A course of deliberate action to allow an item to run to loss of functionality due to economic reasons (cost of failure less than prevention) or unavailability of resources to prevent failure from occurring.
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Schedule Compliance
- Number of scheduled jobs actually completed in the period scheduled, also number of scheduled hours actually worked compared against a planned number of scheduled labor hours as a percentage.
Scheduled Maintenance
- Maintenance that is planned and prioritized to be done at determined time.
Scoping
- Outlining the necessary components and labor requirements for a job.
Self-Directed
- When an organization moves to self-directed work teams, individuals in the organization make many of the decisions while production management merely sets limits on the teams and provides support. Maintenance is incorporated into process or production teams. Team leads are utilized instead of traditional supervisors.
Service Level
- The percentage of times that stock
items are solicited compared to the number of times it is actually issued—opposite
of a stock-out.
Shelf Life
- Period of time that an item in storage can remain in acceptable condition.
Shutdown
- Period of time when equipment is out of service.
Single Point Lesson Plans
- A form of a job aid, but is restricted to one page and one point.
SMART Training
- Start the task
when…, Materials needed
to perform the task are…, Actions to perform are…, Results
will be…, Task standards are… - A format used to help produce
training which is more consistent and reliable than standard on-the-job training
methods.
Sort
- Process used to eliminate unnecessary items, therefore regaining valuable workspace and reducing safety hazards caused by clutter.
Specifications
- Physical, chemical, or performance characteristics to meet design standards.
Sponsor
- Senior management level person who believes in the process and is willing to provide support and influence. They begin the process and serve as a guiding force (either directly or indirectly).
Sporadic Loss
- Loss that is sudden, random, and visible.
Standard
- An agreed upon activity usually in the form of a document with pictures and tasks.
Standing Work Order
- A work order that remains open, usually for the budget cycle, to accommodate information on small jobs and or for specific tasks.
Statutory Maintenance
- Maintenance that must be carried out to meet statutory requirements for compliance.
Steering Council
- A cross-functional mix of leadership organized to support TPR.
Stock-out Rate
- Number of unfilled requests divided by total number of requests made, multiplied by 100.
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- T -
TPR- Total Process Reliability - A
process to improve equipment efficiency by enrolling the entire organization
in incident management.
TPR Coordinator- A full-time staff person who facilitates teams, coaches personnel, and
supports TPR activities on an ongoing basis.
Turnover Rate- Total inventory value divided by the total annual issues (the number of times
inventory turns in a given period, such as a year).
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- U -
Unplanned Maintenance- Maintenance done without advanced planning or scheduling, most often affiliated
with breakdowns or emergencies (EM), running repairs or corrective maintenance
(CM).
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- V -
Visual Controls- Communication devices such as signs, photos, outlines, etc. that communicate
the status of an area at a glance, and communicate how work should be performed
in that area.
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- W -
Work Order- A unique control document that comprehensively describes the job to be
done; may include formal requisition for maintenance work.
Work Request- A request for maintenance work to be performed.
Workload
- Number of labor hours needed to carry out a maintenance program including
all planned and unplanned work.
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- X -
XDTs
- Cross-functional Design Teams – Groups of representatives from various functions
providing key input to the design of the equipment.
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