T P MSource: Kaizen Institute, Frankfurt

In the Past: The Company determines the price.Now and in the future, the Market determines the priceAs costs decrease, Profits increase!Profits decrease as losses ariseQuelle: Kaizen Institute Why T P M ?

Source: Kaizen Institute, Frankfurt Muda and lossesMike Johnson:

Before 1 Severe problem occured, there were 300 minor and 29 major problems to handle.Source: Kaizen Institute, FrankfurtHeinrichs LawTPM is a tool which addresses potential signs of machine break-downs and is therefore an important instrument to prevent total machine crashes.129300Severe problemMinor problemsMajor problems Why T P M ?

Source: Kaizen Institute, Frankfurt Goals of TPMReduction or prevention of losses like:- scrap, rework- machine downtime- unnecessary change oversCreate improvements through ownership!! Recognize weaknesses and make improvementsHave a safe and effective work environment... through the team members

By changing the circumstances the attitude of the team members change.Source: Kaizen Institute, FrankfurtAfter implementation of TPM there is a recognizable change of motivation.More knowledge promotes pride and ownership of the equipment and processes.132Machines 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 BasicsKaizen (Continuous Improvement)TPM (Autonomous Maintenance)Prevention of the six frequent losses.Improvement of the product qualityPlanning system for new machines and equipmentTrainingSecurity and Environemental protectionImprovement of office efficiencyZero FaultsZero defectsZero accidents

Source: Kaizen Institute, FrankfurtInitial cleaning of machines, equipment and surroundingsCountermeasures at the source of problemsCleaning and lubrication standardsGeneral InspectionAutonomous InspectionOrganization and tidinessFullautonomous maintenanceStep 1Step 2Step 3Step 4Step 5Step 6Step 7 Seven Steps of TPM

Why Total Productive Maintenance?Source: Kaizen Institut, FrankfurtWith the implementation of Total Productive Maintenance, Team members will assume ownership for their working processes.PrivateCompanyGasCleanlinessReflector controlOil gageCooling waterTire pressureCleanlinessTools 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, FrankfurtBy training the team members in Total Productive Maintenance, the team members will be able to attend to minor equipment repair by themselves.PrivateCompany Change reflectorRefill cooling waterChange tiresRefill hydraulic oilFix toolsFix screws Attend to equipment change filterChange spark plugs

TPM Step 1Source: Kaizen Institute, FrankfurtSUMMARYGoal:ProcessHint:Therefore:Initial cleaning of the machines and the equipment, lubricate according to lubrication plan, etc.1. Preparation2. Coordination3. TPM workshop4. ReviewOnly clean machines and clean equipment make problems visually apparent!!!CLEANING IS CHECKING !

Source: Kaizen Institute, Frankfurt Goal of step 2Countermeasures at the source of problems - Improves Preventive Maintenance

Source: Kaizen Institute, Frankfurt Cleaning and Lubrication StandardsWhat do we know about standards?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;Humans learn;Through hearingThrough seeingThrough hearing and seeingThrough conversationBy hands on!

Quelle: Kaizen Institute Goals of visual management

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