Total Productive Maintenance
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01
Precision Changeovers
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Total Productive Maintenance
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• Define a changeover in your environment.
• When does changeover start?
• When does it end?
• What the impact on the process?
Changeover?
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The 4 Phase Analysis Process ~ Overview
PHASE
1CURRENT STATE Internals & Externals mixed together
2SPLIT PHASE Separate Internals from Externals
3CONVERSION PHASE Convert Internals to External & Streamline Internals
4
STREAMLINING PHASE Eliminate adjustments & streamline remaining Internals AND externals
PRODUCTA
PRODUCTA
PRODUCTA
PRODUCTA
PRODUCTB
PRODUCTB
PRODUCTB
PRODUCTB
PRODUCT CHANGE TIME
INTERNAL
INT.
INT. INT. INT.EXT. EXT.EXT.
INTERNAL
INT.EXT.
Organisational Improvements
Technical Improvements
Technical / Organisational Improvements
EXT.
EXT.
EXT.
EXT.
Total Productive Maintenance
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Reduction in motion – Spaghetti diagram
BEFORE AFTER
PRODUCTA
PRODUCTA
PRODUCTA
PRODUCTA
PRODUCTB
PRODUCTB
PRODUCTB
PRODUCTB
PRODUCT CHANGE TIME
INTERNAL
INT.
INT. INT. INT.EXT. EXT.EXT.
INTERNAL
INT.EXT.
Organisational Improvements
Technical Improvements
Technical / Organisational Improvements
EXT.
Total Productive Maintenance
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• Roles and Responsibilities– Operator– Maintenance Electrician– Time Keeper– Data Sheet Recorder– Activity Monitor (Spaghetti Diagram)– Improvement Team
Changeover Simulation
Total Productive Maintenance
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Carry out a changeover!
Blue Circles to Red Diamonds
STEP 1:Analyse the Current process
Total Productive Maintenance
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• Identify the start and end of the changeover• Observe the changeover (use video if possible)• Record ALL observations/ideas on post-it notes during changeover (One
fact per post it / be specific / readable / useful facts & phrases)• Record elements of operation and data on changeover analysis sheet
STEP 1:Analyse the Current process
Total Productive Maintenance
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Create the Changeover ChartChangeover
ElementTime
Observations
Internal
External
Streamlining
Savings
New Standard Process
New Time
Operation steps in sequence
Operation time for individual stepObservations / suggestions noted during changeover
Remove Vice
110 secs
STEP 1:Analyse the Current process
Total Productive Maintenance
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Step 1: Analyse the current process
Create the Changeover ChartChangeover
Element
Time
Observations
Internal
External
Streamlining
Savings
New Standard Process
New Time
Operation steps in sequence
Operation time for individual stepObservations / suggestions noted during changeover
Remove Vice
30
110 secs
Raw material by M/C
MS
PRODUCTA
PRODUCTA
PRODUCTA
PRODUCTA
PRODUCTB
PRODUCTB
PRODUCTB
PRODUCTB
PRODUCT CHANGE TIME
INTERNAL
INT.
INT. INT. INT.EXT. EXT.EXT.
INTERNAL
INT.EXT.
Organisational Improvements
Technical Improvements
Technical / Organisational Improvements
EXT.
Total Productive Maintenance
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STEP1:AnalysetheCurrentprocess
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STEP 1:Analyse the Current process
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Changeover Time
84
71
20
102030405060708090
Min
utes
Step 1 Current state
Target
Step 1: Set the Target
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Step2:Separateinternalfromexternal
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Step 2: Separate Internal toExternal Action Plan
• Get tools by machine onto shadow board• Contact electrician in advance• Have earth fitting pre fixed• Plate off/On at station• Setting Standards by line• Pre check Raw Materials• Materials at line
Total Productive Maintenance
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Changeover Time84
71
112
0102030405060708090
Min
utes
Step 1 Current state Target
Progress at Step 2
Step 2
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Step 3: Convert Internal to External
• Discuss every step and every possible technical improvement that can be made at this point to improve and/or eliminate steps.
• Move any technical changes to external where possible.
• Record time saved.
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Step 3: Convert internal to external
Challenge normal thinking……… PRODUCTA
PRODUCTA
PRODUCTA
PRODUCTA
PRODUCTB
PRODUCTB
PRODUCTB
PRODUCTB
PRODUCT CHANGE TIME
INTERNAL
INT.
INT. INT. INT.EXT. EXT.EXT.
INTERNAL
INT.EXT.
Organisational Improvements
Technical Improvements
Technical / Organisational Improvements
EXT.
Total Productive Maintenance
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Step 3: Convert Internal to ExternalUpdate the Changeover Chart & Action Plan
Changeover Element
Time
Observations
Internal
External
Streamlining
Savings
New Standard Process
New Time
Convert internal to external, where possible, and indicate assessment has been made with a diagonal line
Total Productive Maintenance
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Step 3 : Convert Internal to External
• Change tool with Heat resistant PPE to eliminate waiting for tool to cool.
• Place of cooling station at workstation.
• Preheat next tool and place online using PPE.
Total Productive Maintenance
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Changeover Time
84
71
111.1 2
0102030405060708090
Min
utes
Step 1 Current state Target
Progress at Step 2
Step 2
Result
Total Productive Maintenance
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Update the Changeover Chart & Action Plan
Step 4: Streamline & rationalise
Changeover Element
Time
Observations
Internal
External
Streamlining
Savings
New Standard Process
New Time
Ideas / suggestions to make things faster and rationalise operations
Reduce number of bolts?
110 secs
Calculate savings made by streamlining actions
Move all remaining internal elements to ‘New StdProcess’ and calculate new time from any savings
Total Productive Maintenance
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Functional Clamps
Step 4: Streamline & rationalise (internal)
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Step: Streamline & rationalise (internal)
One Turn Methods
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Step 4: Streamline & Rationalise (internal)
Parallel Operations
At bottlenecks use a team for the changeover bringing in operators from non bottleneck machines
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Step 4: Streamline & rationalise (external)
Organisation & Visualisation
(Materials ~ Tools ~ Equipment)
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Step 4: Streamline & Rationalise (external)
SOPs & Checklists
Prepared TPM Team
23/07/2002
Ref No S3-CC-001
Issue 1
Date
Clean all carriage location dowels and report if missing.
Remove any debris and wipe surface area of base plate
Equipment - Dry Cloth, Cleaning Solution, Gloves and Dustpan & Brushes
Wipe the stamping head clean of any contamination
Wipe grease and dirt from front and underside of dummy disc & fixture block
04
121109
0301
Remove any debris and wipe top plate and the Emergency Stop button
02
Wipe surface area of the stamping unit. Take care not to adjust the setting wheel
05
Clean and remove swarf from the vacuum tray and check for suction
06
Wipe left and right cylinders. Take care when cleaning around sensor wiring
07
Wipe clean all brass stops. Push brass block down to confirm its not sticking
08
Wipe central control valve block and take care not to move flow adjustors
10
Wipe conveyor track and trunking of any excess grease and dirt
Team Leader to safely isolate unit prior to clean & check
X 6
AL11 - A140 Changeover Procedure
Operator to immediately inform any problems found to Team Leader
End of Shift
Total Productive Maintenance
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Step 4 : Streamline & rationalise
• Install plug and train ops to use
• Quick release clips
• Locating Pins
• Setting Blocks
• Training
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Step 4: Streamline & rationalise
PLAN• Install plug and train ops to use• Quick release clips• Locating Pins• Setting Blocks• Training
Total Productive Maintenance
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Step 4 : Streamline & rationalise
DO• Install plug and train ops to use• Quick release clips• Locating Pins• Setting Blocks• Training
Total Productive Maintenance
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V2
Step 4 : Streamline & rationalise
CHECK – NEW SOP
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Step 4 : Streamline & rationalise
ACT – RUN CHANGEOVER!
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V2
Step 4 : Streamline & rationalise
ACT – RUN REPEAT CHANGEOVER WITH
SECOND OP