T P M

Source: Kaizen Institute, Frankfurt

In the Past: The Company determines the price.

Now and in the future, the Market determines the price

As costs decrease, Profits increase!

Profits decrease as losses arise

Production costs Profit

Sales Price

Production cCsts Profit

Sales Price

Quelle: Kaizen Institute

Production Costs Profit

Market Price

Why T P M ?

Source: Kaizen Institute, Frankfurt

Muda and losses

Mike Johnson:Mike Johnson:

Before 1 Severe problem occured, there were 300 minor and 29 major problems to handle.

Source: Kaizen Institute, Frankfurt

Heinrich‘s Law

TPM is a tool which addresses potential signs of machine break-downs and is therefore an important instrument to prevent total machine crashes.

1

29

300

Severe problem

Minor problems

Major problems

Why T P M ?

Source: Kaizen Institute, Frankfurt

Goals of TPM

The goal of TPM is to increase efficiency and productivity.

This improves profit margins, our competitiveness and guarantees job security.

Machine

Team Member

The goal of TPM is to maximize the efficiency of machines and technical

equipment.

The goal of TPM is to increase efficiency through

more involvement, participation in making

decisions and joint responsibility

Reduction or prevention of losses like:

- scrap, rework

- machine downtime

- unnecessary change overs

Create improvements through ownership!!

• Recognize weaknesses and make improvements

•Have a safe and effective work environment

... through the team members

By changing the circumstances the attitude of the team members change.

Source: Kaizen Institute, Frankfurt

After implementation of TPM ® there is a

recognizable change of motivation.

More knowledge promotes pride and

ownership of the equipment and

processes.1

3

2

Machines and surroundings

change.

People change/adapt.

The culture changes.

TPM is a registered trademark of the JIPM (Japanese Institute of Plant Maintenance)

T P M philosophy

Source: Kaizen Institute, Frankfurt

8 TPM Basics

Kaizen (Continuous Improvement)

TPM (Autonomous Maintenance)

Prevention of the six frequent losses.

Improvement of the product quality

Planning system for new machines and equipment

Training

Security and Environemental

protection

Improvement of office efficiency

Zero Faults Zero defects Zero accidents

Source: Kaizen Institute, Frankfurt

Initial cleaning of machines, equipment and surroundings

Countermeasures at the source of problems

Cleaning and lubrication standards

General Inspection

Autonomous Inspection

Organization and tidiness

Fullautonomous maintenance

Step 1

Step 2

Step 3

Step 4

Step 5

Step 6

Step 7

Seven Steps of TPM

Why Total Productive Maintenance?

Source: Kaizen Institut, Frankfurt

With the implementation of Total Productive Maintenance, Team members will assume ownership for their working processes.

Private Company

Gas

Cleanliness Reflector control

Oil gage

Cooling waterTire pressure

Cleanliness Tools ok?

Enough lubricant?

Enough coolant?

Clean filter?

Examples of maintenance similarities in private life and in the company.

Why Total Productive Maintenance?

Source: Kaizen Institute, Frankfurt

By training the team members in Total Productive Maintenance, the team members will be able to attend to minor equipment repair by themselves.

Private Company

Change reflector

Refill cooling water

Change tires

Refill hydraulic oil Fix tools

Fix screws Attend to

equipment

change

filter

Change spark plugs

TPM Step 1

Source: Kaizen Institute, Frankfurt

SUMMARY

Goal:

Process

Hint:

Therefore:

Initial cleaning of the machines and the equipment, lubricate according to lubrication plan, etc.

1. Preparation2. Coordination3. TPM workshop4. Review

Only clean machines and clean equipment make problems visually apparent!!!

CLEANING IS CHECKING !

Source: Kaizen Institute, Frankfurt

Goal of step 2

Countermeasures at the source of problems - Improves Preventive Maintenance

Look for causes of contamination

Take corrective actions to prevent the contamination

Improve the maintenance possibilities

These activities have the greatest success if there is a team with members of Maintenance, Production and Engineering.

Source: Kaizen Institute, Frankfurt

Cleaning and Lubrication Standards

What do we know about standards?

Standard 1:

Color code the lubricant

Standard 2:

Color code the oil can in the same color

Standard 3:

Color code the re-fill inlet in the same color

Standard 4:

Make the min/max fill heights visually apparent

For example:

How to achieve a correct refill of a hydraulics tank using a standard.

Quelle: Kaizen Institute

Why Visual Management?

The information reception of a human being happens via;

Eye: 83 %

Ear: 11 %

Sense of smell: 3.5 %

Sense of touch: 1.5 %

Sense of taste: 1 %

Humans learn;

Through hearing

Through seeing

Through hearing and seeing

Through conversation

By hands on!

Quelle: Kaizen Institute

Goals of visual management

Visualize strength and weaknesses

Visualize structures and processes

Show trends and corrective actions

Create visual standards