TPM Training HON Torrance

TOTAL PRODUCTIVE MAINTENANCE

Introducing Total Productive Maintenance (TPM)

TPM increases production and lifts availability by improving equipment and machinery health.

Requirements for a Successful TPM Introduction

Honeywell Confidential - © 2016 by Honeywell International Inc. All rights reserved.

Learning objectives2

• Understand the goals & objectives of TPM• Understand how to measure the

effectiveness of equipment

• Understand the elements of TPM–Keys to success–How does it apply here?

• Prepare for TPM implementation

1

2

3


What is TPM?3

Total Productive Maintenance

A “lean” maintenance strategy for maximizing equipment reliability

Eliminate Equipment Related Waste (Gemba)

Share Responsibility for Equipment Reliability

An organizational philosophy of everyone appreciating and caring about company assets and realizing that everyone’s job directly or indirectly affects those assets

A shift from “I operate it, you fix it” to “Our team is the best in the business!”


What is the value of our Equipment?4

TPM aims to leverage the full value of equipment


Overall Equipment Effectiveness5

How do we measure TPM?To support product flow, machines and equipment must:

Run when needed (Availability)Run at the rate needed (Performance)Yield the required result (Quality)

Overall Equipment Effectiveness:OEE = (% Availability) (% Performance Efficiency) (% Quality Rate)

Throughput Rate120% (danger here – high stresses in parts)

Name Plate

80% (Under perform)

Availability = Uptime . Uptime + Downtime80% = down 73 days90% = 36.5 days95% = 18.25 days98% = 7.3 days99% = 3.65 days99.9% = 0.365 days

Product Quality(Six Sigma Method)

First Pass Yield6δ - 99.99966%5δ – 99.977%4δ – 99.38%3δ - 93.32%2δ - 69.15%1δ – 30.8%


Six Big Losses6

Breakdowns SlowdownsProduction Rejects

Start-up Rejects

Setup and Adjustments

Stoppages

Availability Loss Quality Loss Throughput Loss

• Tooling Failures • Unplanned Maintenance • General Breakdowns • Equipment Failure

• Setup/ Changeover • Material Shortages • Operator Shortages • Major Adjustments • Warm-Up Time

• Obstructed Product Flow • Component Jams • Misfeeds • Sensor Blocked • Delivery Blocked • Cleaning/ Checking

• Rough Running • Under Nameplate

Capacity • Under Design

Capacity • Equipment Wear • Operator Inefficiency

• Scrap • Rework • In-Process Damage • In-Process Expiration • Incorrect Assembly

• Scrap • Rework • In-Process Damage • In-Process Expiration • Incorrect Assembly

Issues Identified through Visual Management should be addressed with Rapid Problem Solving and Kaizen


Shared Responsibility7

Operators

Engineers

Maintenance

Management

Equipment Reliability


Shared Responsibility88

• Prevent deterioration• Measure effectiveness

– Availability– Performance– Quality

• Report or correct abnormalities• Participate in improvement

• Provide technical support to operators• Train operators• Perform major repairs/overhauls• Improve preventive/predictive

maintenance• Participate in improvement

• Identify Critical Equipment• Implement equipment improvement ideas• Engineer improvement solutions• Provide technical/training support• Communicate with operators and

maintenance

• Communicate plans, goals, expectations• Provide resources • Recognize and reward success• Lead by example

Operators Maintenance

Engineers Management


TPM Maturity9

Stage I

Reactive

Stage II

Preventive

Stage III

Predictive

Stage IV

Proactive

• Fix when Fails

• Repair / Replace

• Limited Data

• Clean & Inspect

• Time Based

• Equipment Dataavailable

• Monitor

• Condition Based

• Data analysis

• Asset Management is FMEA-based

• On-line performance intelligence and correction

• Designed for ReliabilityWhere are we?


Planned Maintenance10

• Planned Maintenance should increase the maintainability and the reliability of our equipment!

Maintainability – Minimize the mean time to restore (MTTR)

Reliability – Maximize the mean time between failures (MTBF)

• Planned Maintenance can increase stability• Stability is the foundation for further improvements


Critical Equipment Daily Status11

Equipment Name PCN Cell Value Stream Current StatusOverall

AvailabilityMTTR(days)

MTBF(days)

Estimated Completion Date

First Day for Annual PM

Last day for Annual PM

Baker Process Line 058030080 4 VS1

De-Emulsifier pump is leaking. Calling in Safety Kleen on 7-6-16 to repair it. UPDATE 7-11-16,

Safety Kleen called back and said they started a ticket on it. No ETA. 100% 1 336 TBD 1/2 5/3

C-6 Process Line 047100006 4 VS1 99% 3 328 #N/A #N/A

Carbon Adsorbtion 024090010 4 VS1 100% 1 2442 10/29 2/27

Ozone Converter Room 4 VS1 99% 4 383 #N/A #N/A

Quench Furnace (Furnace# 10) 030070104 4 VS1

99% 2 269

#N/A #N/A

Ramco Line 047100019 4 VS1 100% 1 1266 2/8 6/9

Salt Bath & Pre-Heat Ovens 030010014 4 VS1 100% 2 431 1/2 5/3

CO2 Laser 031010131 5 VS1

Laser is losing power, contacted SBA they want operator to monitor when problem occurs and will

schedukle return service call. UPDATE 6-15-16, Power stays up with fan on vacuum pump. Sending

spare pump out for rebuild. 98% 3 172 TBD 1/8 5/9

7/15/16 - WM


Equipment Name PCN Number template12

Equipment Name

PCN NumberCurrent Status Preventive Maintenance

Annual PM Window

For Maintenance Call 512-5980 Last Annual PM Date% Uptime MTTR (days) MTBF (days)

Daily Operator Maintenance

Monday Tuesday Wednesday Thursday Friday Saturday Sunday


Autonomous Maintenance (Operator task performed)

13


Autonomous Maintenance (Operator Task Performed)

14

• Who knows better how a given machine should perform, sound, function, etc. than the person who interacts with the equipment every day.

• Daily cleaning and maintenance tasks should be designed into the operator’s standardized work and the housekeeping standards should be made as visual as possible.

Equipment Kaizen• Equipment should be designed to reinforce the operator’s standardized work • Equipment Kaizen is used to eliminate the six losses and to improve equipment performance


TPM Checklist15


Visual Management16

Date post:	08-Feb-2017
Category:	Documents
Upload:	wayne-miller
View:	84 times
Download:	5 times

TPM Training HON Torrance

Documents