Ch.3 TPM Introduction.pdf

8/19/2019 Ch.3 TPM Introduction.pdf

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Introduction to TPM

by

R.M. Sugengriadi, ST., MT

Introduction to TPM

by

R.M. Sugengriadi, MT


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Toyota Production System

Adaptation to Japanese Stylefrom “Preventive Maintenance” - USA - 1951

History of TPM


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History of TPM

PMProductive

Maintenance

Preventive Maintenance PM 1951Physical checking of Equipment to find faults and fix before problems manifest themselves

Corrective Maintenance CM 1957An expansion of Preventive maintenance where the focus is on the improvement of equipment so that:

Failure can be eliminated quickly (Reliability)

Maintaining becomes easier (Maintainability)

Maintenance PreventionMP 1960

Designing equipment to be maintenance free

Productive MaintenanceThe use of all three techniques across the life cycle of the equipment. PM + CM + MP

1951 1957 1960 1980’s

PMPreventive

Maintenance

CMCorrective

Maintenance

MPMaintenance

Prevention

CBMCondition

Based

Maintenance


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Measurement, Documentation, Communication, Involvement and 5S

S a

f e t y / H y g

i e n e

& w o r k

i n g

e n v

i r o n m e n

t

E n

v i r o n m e n

t

C u

s t o m e r

S e r v

i c e

F o

c u s e

d I m p r o v e m e n

t

A u

t o n o m o u s

M a

i n t e n a n c e

P r

o f e s s

i o n a

l

M a

i n t e n a n c e

E a

r l y

E q u

i p m e n

t

M a n a g e m e n

t

T o

t a l P r o

d u c

t Q u a

l i t y C o n

t r o

l

P e

o p

l e D e v e

l o p m e n t

C o

s t R e

d u c

t i o n

World Class Manufacturing

Focused TPM

The TPM Pillars – Types of TPM

Type 1 = Business change strategy


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Type 2 = Focused TPM

F o c u s s e

d I m

p r o v e m e n

t

A u

t o n o m o u s

M a

i n t e n a n c e

P r o

f e s s

i o n a

l M a

i n t e n a n c e

E a r l y

E q u

i p m e n

t

M a n a g e m e n

t

W C M

L o s s a n d C o s t

5 S

F o c u s s e d T P M

Asset Care – Looking after our Machines


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WHY TPM?


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Why TPM?

Increase

Productivity

ImproveCustomer

Satisfaction

Improve

Quality

Improve

Processes

Reduce Line Stoppages

Reduce Unused TimeReduce Low Speed Operations

On Time DeliveryGiving the customer what they asked for

At the quality expected

Right First Time

No rejects/dump - NO wastage

Reduce variation in specifications

Work at standard time

Improve the standard times to best inEurope

Develop good production plansKnow the processes

Competitiveness

R e

d u c e

C o s

t s

I n c r e a s e

S a

l e s

I m p r o v e

M a r k e

t S h a r e

Business Need Business Needs


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Why TPM?

} SAFETY

} NOT HARD WORKSMART WORK

} TEACH ONEANOTHER

Physical

Environment

Learning

Environment

Social

Environment

Management

Style

Clean

Structured

Effective

Good Place to work

Learn about machines

Learn about processes

Learn about products

Learn about systems

Work as a team

Create time to "think" - Improvements

More interesting jobs

Develop a Success CultureListen and Build on each others ideas

Less manual work

Less "tiring" work

Less "rushing around"

New Management style

Coach to Big Boss !!

Support NOT You Do This !!

Understand the consequences of changingpriorities

Work

Environment

People Development

D e v e

l o p

S t a f f


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To restructure the corporate culture through

improvement of human resources and plant equipment

Improving

human

resources

Educate and foster employees so that they can respond to the needs of Failure Analyse(1) Operator : Ability to perform "Autonomous Maintenance"

(2) Technician : Ability to perform high-quality maintenance

(3) Project engineer : Ability to execute maintenance-free equipment

Improving

plant

equipment

(1) Attain efficiency through revamping of the existing equipment

(2) Life Cycle Costing considered design of new equipment and

minimising their run-up time

Improving of corporate cultureImproving of corporate culture

What TPM aims at:


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What do we want?

SEESEE

CHANGECHANGE

VISUALVISUALSUCCESSSUCCESS

World ClassWorld Class

ManufacturingManufacturing


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The Factory Environment

Electrical Drawing ?Mechanical Drawing ?

Software version control?

Inter shift communications ?

Machine settings ?Quality standards and control data ?

Operational Standards ?

Personal Standards ?

Line Owership ?

Machines that are (3D's)

Dirty, Difficult, Dangerous to use

STANDARDS

CULTURE

LEADERSHIP

OWNERSHIP


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What is TPM?


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TPM Definition

“TPM identifies, then seeks to eliminate all the major

equipment and process wastes by involving and utilising

hidden skills and abilities of the company’s workforce by

ocused continuous improvements, whilst changing and

invigorating the corporate culture and making the workingenvironment more pleasant, safer and enjoyable”


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Total

Productive

Maintenance

TPM Definition

Involving Everyone & Everything

Striving to operate at above

average performance

Maintaining / Sustaining


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TPM Culture

M/C Losses

Waste

Accidents

Defects

Breakdowns


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Total Productive Maintenance

BY USING THE

PILLARS of FOCUSED TPMTO ACHIEVE

ZERO DEFECTS

ZERO BREAKDOWN

ZERO WASTE

ZERO ACCIDENTS

1. FOCUSED IMPROVEMENTS

2. AUTONOMOUS MAINTENANCE

3. PROFESSIONAL MAINTENANCE

4. TRAINING & EDUCATION

5. EARLY MANAGEMENT.

ELIMINATING THE

"SIX MAJOR LOSSES"

1 Equipment Failure

2 Changeover Losses

3 Startup Losses

4 Minor Stoppages & Idling Losses

5 Speed Losses

6 Quality Defects

44

ZerosZeros

Using OEE Metric to

drive the improvement


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Total Productive Maintenance

6 B I G

L O S S E

S

StartupLosses

Set up &Adjustments

Reduced SpeedLosses

Quality Defects

And Rework

Idling &Minor Stoppages

Breakdowns

Facility / Equipment

Oil temps, water temps, ambient temps, sticking of components,

lateness, absenteeism, etc.

Water flow rate, air pressure, oil pressure, mains

voltages, tip counters, heat stepping, oven temps, etc

Robot switched out, motor/s running slow,

Feeds + Speeds incorrect, etc

Surface Finish, paint runs, parts

not to spec, difficult to fit, etc

Blocked / starved,

shortage of parts, etc.

Tips out,

sealer/paint

guns blocked

Catastrophic

failure.

Major/Minor


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60%

100%

month

OEE

666666

544444

433333

322222

21

111

11

Goal

The

Gap

ELIMINATING THE

"SIX MAJOR LOSSES"

1 Equipment Failure

2 Changeover Losses

3 Startup Losses

4 Minor Stoppages & Idling Losses

5 Speed Losses

6 Quality Defects

OEE

TPM Focuses on the Gap


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Why is TPM Important ????

Job SecurityJob Security

Improved QualityImproved Quality

Increased CapacityIncreased Capacity

Improved ProfitsImproved Profits

Improved UptimeImproved Uptime

ImprovedImproved ThruputThruput

Better ProductivityBetter Productivity

Improved SkillsImproved Skills

Safer WorkingSafer Working

EnvironmentEnvironmentBetter Work Better Work

More Active inputMore Active inputto Job Contentto Job Content

The Benefits

Are Real !

EnvironmentEnvironment

Job SecurityJob Security


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So What does TPM do ...

“TPM finds the realproblems in our factories

that lead to waste of time,

materials, energy and

eliminates unplanned

M/C downtime


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"Our Secret Weapon"Our Secret Weapon““ and Team Work and Team Work

"Finding and solving these"Finding and solving these

problems using you theproblems using you theTeam"Team"

World Class Manufacturing World Class Manufacturing

So What does TPM do ...

"Creating a culture and"Creating a culture and

environment where smartenvironment where smartwork breeds success"work breeds success"


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TPM in the CI Process

5 S0

2

4

6

8

10

12Manufacturing

Goals

TIME

.

Loss & Waste

Why - Why Analysis

Focused

Improvements

"What's

holding you

back"

PDM

One Point Lessons

Training

7 Steps

Breakdown

PlannedPredictive

Professional

Maintenance

1. Cleaning with Meaning

2. Restoration

3. Standards

}

"Eyes & Ears"

of Production

Autonomous

Maintenance

Project Mangt

InnovationDesign for Manufacture

Early Equipment

Management

5 S

Manufacturing Equipment Care is AM & PM


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Aims of Maintenance

Sustain

ZERO FAILURESZERO FAILURES

To maintain

Maximise plant availabilityMaximise plant availability

at an economical costat an economical cost


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Why does equipment fail ?

TimeTime

DeteriorationDeterioration

.. ..

ForcedForcedDeteriorationDeterioration

NaturalNatural

DeteriorationDeterioration

DETERIO-RATION

INCREASEDSTRESS

INSUFFICIENTSTRENGTH

FAILURE

1

2

3

4

5

6

FAILURE TOMAINTAIN BASIC

CONDITIONS

FAILURE TOOBSERVE

OPERATING

CONDITIONS

FAILURE TORESTORE

EQUIPMENT(ELIMINATE

DETERIORATION)

DESIGN

WEAKNESS

INSUFFICIENT

OPERATOR SKILLS

INSUFFICIENTMAINTENANCE

SKILLS

EXTERNAL INF

DEFECTIVE PART

WEATHER

MAT, UTILITIES


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World Class Maintenance Strategy

for Equipment Care

Improvement Activities

Maintenance ActivitiesPeriodic Maintenance

Time based maintenance – conducting repair andreplacement based on pre defined machine time intervalsTo Prevent Failures

To Extend LifeTo Avoid Maintenance

Kaizen Approach- Reliability & Maintainability

Design Maintenance Free

Design for Manufacture

Predictive MaintenanceCondition based maintenance – monitoring & inspectingequipment and to defect and eliminate breakdowns

Overhaul Full inspection and repair – the equipment is regularly

disassembled to be inspected and repaired

Autonomous MaintenanceBasic maintenance – ensuring the equipment isclean, lubricated, secure and operated correctly

BreakdownThe equipment is allowedto breakdown before repair

PreventiveSystems are established to stop

Breakdown occurring.

CorrectiveThis is the improvement activitieswithin the Maintenance strategy

P R O F E S S

I O N A L

M A I N T E N

A N C E

P R O F E S S

I O N A L

M A I N T E N

A N C E

Maintenance ThrustsMaintenance Thrusts Maintenance StrategiesMaintenance Strategies Maintenance ProgrammesMaintenance Programmes

MaintenancePrevention

Providing maintenance knowledgelearning on existing equipmentto develop and purchase new

equipment

Breakdown Analysis

Repair breakdowns

Root Cause Analysis

O P E R A T O R S

T E C H N I C I A N

T E C H N I C I A N Emergency Work Order 5W & 1H & Problem Solving


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Focused TPM = Asset Care

S u p p o r t

A u

t o n o m o u s

M a i n t e n a n c e

Z e

r o F a i l u r e

A

c t i v i t i e s

E s t a b l i s h a P e r i o d i c

M a i n t e

n a n c e S y s t e m

T

r a i n i n g &

E d

u c a t i o n o f

M a i n t e n a n c e S t a f f

O i l &

L u b r i c a t i o n

M a

n a g e m e n t

E s

t a b l i s h a n

I n

f o r m a t i o n

M a n a g

e m e n t S y s t e m

S p a r e

P a r t s S y s t e m

E n g i n e e r i n g

W

o r k s h o p

E s t a b l

i s h a P r e d i c t i v e

M a i n t e n a n c e S y s t e m

Professional MaintenanceSub Pillars

P r o

f e s s

i o n a

l

M a

i n t

e n a n c e

A u

t o n o m o u s

M a

i n t e

n a n c e

Step Contents Of Step

0 Education - machine function & condition

1 Initial Cleaning & Inspection.

2 Countermeasures to eliminate sources of contamination

and "hard to access" areas.

3 Develop provisional standards for cleaning, lubrication

and tightening.

4 General Inspection - Training & Instruction of the

finalized standards.

5 Autonomous Inspection

6 Reorganizing workplace & Standardisation

7 Full Implementation of Autonomous Management


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THANK YOUTHANK YOU

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Ch.3 TPM Introduction.pdf

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