1

TPM in the connected factory

Japan Institute of Plant Maintenance

Senior Researcher Zensuke (Zen) Matsuda

Dec. 201６

UK TPM Seminar

T….. Total P….. Productive M…. Maintenance Management TPM is the holistic, structured and quantifiable methodology to seek productive excellence by eliminating losses. TPM is a concept rejuvenating itself with experience of many users.

2

TPM

Actual Scene/Thing

Humanity

Zero loss

Sustainability

Preventive

Rejuvenation

3

History of TPM 1950 1960 1970 1980 1990 2000 2010

1982

1971

2000

1951

Breakdown Maintenance

Preventive Maintenance

TPM(21st Century)

TPM (Total Productive Maintenance)

TPM (Company- wide)

1960 Productive Maintenance

Preventive

Operator Participated

Entire Company

Innovative

Awarded factory / Industrial Classification

Machine work & Assembly Industry 1,341 Process Industry 1,838

Automobile and Other Motor Vehicle 123 Iron and Steel & Non-Ferrous Metal Products

221

Automotive Parts & Accessories, and Transportation Equipment

642 Chemicals 335

General Industrial Machinery & Equipment, Precision Apparatus

127 Textiles 84

Semiconductor & Electronic Equipment 213 Rubber & Plastic Products 196

Consumer Electronic Appliances, Information Communication Electronics Equipment

99 Food & Beverage 503

Fabricated Metals 103 Drug & Medicine 26

Housing & Woodwork 34 Pulp & Paper 166

Printing 98

Cement & Ceramic Products 93

Electric Power & Gas, Petroleum and Coal 118

Others 70

Year : 1971-2015 Total 3,249.

4

5

TPM Awards to Tetra Pak

Global Leaders’ Initiative Award

World Class Award

Tetra Pak Production d.o.o.

Gornji Milanovac, Serbia

23 March 2016 Tetra Pak Home Page :Tetra Pak Receives the

World’s Most Prestigious Manufacturing Award.

Mr. Lars Wennberg

Vice President

Terta Pak

Empowered people deliver

breakthrough results!

http://www.tetrapak.com/

about/newsarchive/tetra-

pak-receives-the-worlds-

most-prestigious-

manufacturing-award

Keynote Speech

Zen-in sanka

(All members

Participation)

Factory Supply Delivery

Equipment

Producer

Material

Supplier Customer

Planning

Product

Development

TPM Activity Progress

Company

Administration

Connected

Business Chain

Outsourcing

Io

IoT: Internet of Things

Cyber Physical System

AI: Artificial Intelligence

Asset Management

Data Analysis Standardization

ISO/IEC

6

7

KMI/KPI/KAI(Example)

KMI : Key Management Indicator

KPI : Key Performance Indicator

KAI : Key Activity indicator

OEE

Claim, Quality

Cost Reduction

Lead Time

Save Energy, etc.

ＫＰＩ

Skill Management

Co-development with Customers, FMEA,FTA

Quality of Modules, Supplier Assessment, QFD

KAIZEN, New Material Evaluation, etc.

“MAKIGAMI” （Process Step Reduction), VSM

Energy Conservation, Wastes Reduction

ＫＡＩ:Number of Kaizens and Activities

Seminar, Qualification, Certification

Ｐ Defect Tag, OPL, PM-Analysis, RCM

Ｑ

Ｃ

Ｄ

Accidents Near Accidents finding, Essential Safety Design Ｓ

Ｅ

Ｍ

ＫＭＩ ①Revenue ②Profitability ③Safety ④Quality

OPL: One Point lesson

PM-Analysis

P:Phenomena/Physical

M:Mechanism/Machine

/Method/Material/Man

RCM: Reliability-Centered

Maintenance

FMEA: Failure Mode

Effects and Analysis

FTA：Fault Tree Analysis

QFD：Quality Function

Deployment

VSM: Value Stream

Mapping

New Product Ratio

KPI

Lo

ca

l Fa

cto

ries

S:Safety

P:Productivity

Q:Quality

C:Cost

D:Delivery

E:Environment

M:Moral

KAI

KPI

KMI (….)

KMI (New Product)

KMI/KPI/KAI & Loss-Cost Matrix

8

KMI (Profit)

Cost Structure Cost Reduction Target

Loss Finding

Kaizen

KPI

Evaluation

Strategy

plan

do

check

action

Leadership

KMI (Revenue)

KAI

Management

Standardization

Loss Cost Matrix

SOP

(Standard Operating Procedure)

KMI :

Key Management

Indicator

KPI :

Key Performance

Indicator

KAI :

Key Activity

indicator

9

KPI Performance Improvement/Year

Data: From 2012TPM Award winners (World-class～Consistent)

Energy: 2014 TPM Award winners

Customer

Complaints

Δ%/Year

12%

OEE

1.7%

Δ%/Year

≒+2%/Year -12%/Year

Accidents

Δ%/Year

9%

-9%/Year (Minor Accidents)

-10

-9

-8

-7

-6

-5

-4

-3

-2

-1

0

Energy

-4.9%/Year

4.9%

Δ%/Year

TQM/TPM/TPS

10

Respect

for

Humanity

TPS

・KANBAN

(Index Board)

TQM TPM

・Quality

Function

Deployment

・Loss-cost

Matrix

・Just in Time

・Autonomation

・Autonomous

Maintenance

・Loss Zero

・Statistical

Process

Control

・Policy

Management

・ANDON

(Signboard)

・KARAKURI KAIZEN

・QC 7 tools

Efficiency Reliability

Excellence

・OEE:

（Overall

Equipment

Efficiency）

・Heijunka

(Process Smoothing)

・Waste/ Unevenness/ Strain

Elimination

・Poka-yoke

(Failsafe)

・Tanpin Kanri

(Management by single product)

・GENBARYOKU

(Wisdom of work place)

(Total Quality Management) (Total Productive Maintenance)

(Tyota Production System)

11

TPM: A Foundation for Asset Management

MAINTENANCE

TECHNOLOGY

Sept. 2014

Editor:

Bob Williamson

CMRP, CPMM,

and Member of

Institute of

Asset Management

12

Past

Present

Future

Target

Present

Situation

Gap=Loss TPM

ISO55000s

“Productivity” is an attitude of mind.

It is the will to improve on the present situation, no

matter how good it may seem, no matter how good it

may really be.

(European Productivity Agency1958)

Asset Management & TPM

Line of sight

Zen-in sanka (All members Participation)

Top Down and Bottoms Up for Excellence

13

Top ・Goal

Middle ・Target

Operation ・Motivation

Line of sight

Zen-in sanka 全員参加 (All members Participation)

If abnormality happens, operators are authorized to stop a line, and find out a true cause in "Zen-in sanka" way.

Global Innovation with IoT

Industry 4.0

Industrial Internet

CPS: Cyber Physical System AI: Artificial intelligence

14

Revolution in Manufacturing

Cyber Physical System

Simulation

Servitaization Development

AI : Abnormality

detection

Open

Source

(Prod.)

Customer

CAD

Real time Indicators

KMI/KPI/KAI

Real ⇒Digital

AI：Data Analysis

AI：Knowledge &

Experience

Real

Cyber

Real

Spare parts

（Hard/Soft/Webb

/3D printing）

15

Production

Management

Digital ⇒Intelligence

Intelligence ⇒Real Open

Source

(Design)

Experiment

16

Innovation in Maintenance Technology

Data (Inductive)

Mo

de

l(De

du

ctiv

e)

Simulation

Theory Data Analysis

Experience

Cyber Physical System

Deep Learning

Ex).LES: Large Eddy Simulation

Ex).SVM: Support Vector Machine

Ex).Self-Organizing Map for Reinforcement Learning

IDEMITSU ENGINEERING CO.,LTD.

Confidential Copyright © 2015 by IDEMITSU ENGINEERING

CO., LTD. (IEC)

To be reproduced and used only in accordance with written

permission of IEC

Duct Gas flow Analysis

改善後

Introduction of Highly Precise Simulation

LES(Large Eddy Simulation)

17

After Improvement

Frequent breakdown

Deep Learning

Preferred Networks

18

Application of AI(Artificial Intelligence)1

http://www.renesas.com

Renesas

Data Acquisition

High Speed

Low Power

Real Time

communication

Data Analysis

Machine

learning

Artificial

Intelligence

ＸCompass intelligence Ltd

http://www.xcompass.com

Anomaly

Detection Predictive

Maintenance

MES(Manufacturing Execution System）

SCADA（Supervisory Control And Data Acquisition）

19

Renesas Electronics Corporation

R-IN+AI

MES or SCADA

Ethernet Add-on to Ethernet

Application of AI(Artificial Intelligence)2

Mo

nito

red

Da

ta Manufacturing day

Equipment

Breakdown

Early Prediction

become available

Input Wave

Wave Form

Generated by AI

Error Wave

Learning normal wave form

High Speed Sampling (50ms)

20

New Threshold enables

Abnormality Detection

X6 Higher than conventional method

Mo

nito

red

Vo

ltag

e

V

V

Normal

Abnormal Gap between learned Normal wave

and abnormal wave

Threshold level (Conventional)

Conventional

Threshold

can not detect

Abnormality

Threshold (New)

0

50

100

150

2015 2040

0

20

40

60

Japan UK USA

21

-25%

Work force decline

Tohmatsu Venture Support Co., Ltd

Replaceable by AI & Robot in 10-20 years

49%

35% 47%

Total population

Work force

(Million)

Nomura Research Institute & C. Frey and M. Osborne (Univ. of Oxford)

The Future of Japanese Work Force

Replace Priority 1. Heavy / Dirty / Dangerous 2. Multi / Speedy / Restless

( Japan center for Economic Research)

Monthly Cost / person(robot)

( Softbank)

Japan $2300 China $640 Robot $160 ( 24H / 5 years dep.)

128 107

77 58 -16%

Human skills required in IoT, I-4.0 era①

Ste

p

８

７

６

５

４

３

２

１

Poor Operation

Can do operation

Do with confidence

Can teach

Simple

Heavy

Dirty

Dangerous

operation

Robots

Karakuri

-Kaizen®

Assisted by

AI, IoT

Big data

Human

Centric

Empowered Operator

Recovering

Anomaly detection

Condition Setting

Maintain

Scope

Traditional

Operator

22

(Can invent)

Autonomous

Maintenance

Operator

Certification for Skilled Operators

Number of Certified Skilled Operators (Autonomous Maintenance) exceeds cumulatively 130,000 in Japan

Correct Monodzukuri

(Manufacturing) knowledge

Jishu-Hozen-Shi

Monodzukuri Test in Thailand

Deployed in Thailand from 2014

English version textbook has started sale in May 2016

Monodzukuri Test all over the world !!

Next Step ･・

23 Analysis service

24

Karakuri Kaizen®

Ste

p

８

７

６

５

４

３

２

１

BDM: Breakdown

TBM: Time Based

PDM: Predictive

Maintenance

Prevention

Needs and data

FMEA Risk

Simulation

Design & Development Designer

oriented

Conventional

Maintenance skills

Partially

transfer to

Empowered

Operators

Collaboration

with IT &

Design

Intelligent

IT oriented

Sensors

Deep Learning

Cyber Physical System

Scope

Analysis

25

Human skills required in IoT, I-4.0 era②

Empowered Maintenance Expert

Traditional

Maintenance

Expert

26

Japan’s activity on IoT , Robot

Robot Revolution Initiative

Industrial Value chain Initiative

https://www.iv-i.org/en/index.html

https://www.jmfrri.gr.jp/english/

http://www.iotac.jp/en/

IoT Acceleration Consortium

http://www.meti.go.jp/press/2016/04/20160428011/20

160428011.pdf

Cooperation between Platform Industrie 4.0 Germany and Robot Revolution Initiative Japan (28. April 2016) Joint Statement WG1: WG for manufacturing

business revolution through IoT

Efficient Value Chain migration with open and closed strategy

Business matching, Financial Support, Regulatory Reform

Bridged by METI

Manufacturing

Manufacturing All area

METI: Ministry of Economy, Trade and Industry

27

Robot welcomed Chancellor

Global standard & Practice

“de jure”

“de fact”

“de pratique”

Industry 4.0

IoT: Internet of Things

CPS: Cyber physical System AI: Artificial Intelligence

28

Industrial Internet

TQM/TPM/TPS

(6σ/TPM/Lean)

Luck brought by heaven

Advantage of geography

Harmony of human

3 Wisdoms for Success

天

地

人

(Heaven)

(Ground)

(Human)

(by Mencius)

Robot Revolution Initiative

Industrial Value chain Initiative https://www.iv-i.org/en/index.html

https://www.jmfrri.gr.jp/english/

Why “Human view point” is important?

29

Industry Revolution Risk

1st Vapor, fossil fuels (Power) Global warming

2nd Electricity, Quantum Mech. (Energy) Atomic bomb

3rd Computer & Communication (IT) Hacking

4th Cyber Physical System, AI Singularity

Negative aspects of Industry Revolutions

Delay of preventive measures

may cause human extinction.

Only Human can cope with it.

“Respect for Humanity” is the base for sustainability.

“Luck brought by Heaven is less than advantages of Geography.

Advantages of Geography is less than Human harmony.” (by Mencius)

Maintenance & Sustainability

30

I believe that TPM activity will strongly support strategies that effectively accomplish sustainability and growth of business. Late Mr. Tokutaro Suzuki Late Mr. Seiichi Nakajima

Message from Mr. TPMs

The basic philosophy of TPM must be the contribution to the sustainability of companies or society.

Actual Scene/Thing

Humanity

Zero loss

Sustainability

Preventive

Breakthrough