Slide 1

Total Productive Maintenance

TPM

Overview

Dave Hoyte, CEOJL French Corporation

Slide 2

TPM as a Lean Initiative

• Competitive costs require– Spending control– Defect control – Downtime reduction

• TPM = Total Productive Maintenance– Proactive (with all employees involved)– Preventive– Predictive– Planned

Slide 3

Why Change?

• ACTIONS:– Reduce defectives / scrap– Reduction of lost production time– Lowest possible cost by reducing waste

Slide 4

Lean System

5S Visual Factory

T P MStandardized

Work

Leadership by Example & CommitmentIn-Station Process Control

Lean Measures

Employee Involvement & Mutual Respect

Pull system / flow production

Peak Performance

Variation reduction / Six Sigma

Continuous Waste ReductionRapid Changeover / Customer-driven lot size

Slide 5

7 Wastes

• Transportation• Excess production• Added processes• Motion

• Waiting• Inventory• Non-conformance (defectives)

Slide 6

Causes of Waste• Excess Manning

– Poor layout and material presentation– Rework and extra processes – Inconsistent / inefficient work methods

• Excess Downtime– Tooling condition – Unreliable equipment– Long changeovers– Incapable process

• Defectives - Rework or Replace– Incapable processes or process not compatible with

customer expectations or design spec (design for mfg)

– Tooling condition– Operator methods and errors

Slide 7

Causes of Waste• Excess Manning

– Poor layout and material presentation– Rework and extra processesRework and extra processes – Inconsistent / inefficient work methods

• Excess Downtime– Tooling condition Tooling condition – Unreliable equipmentUnreliable equipment– Long changeovers– Incapable processIncapable process

• Defectives - Rework or Replace– Incapable processes or process not compatible with

customer expectations or design spec (design for mfg)– Tooling conditionTooling condition– Operator methods and errors

Slide 8

Effective TPM Eliminates 5 Losses

1. Equipment breakdowns2. Defects, scrap, and rework3. Safety Issues4. Mini stoppages5. Reduced speed

Slide 9

What is TPM??

1. Starts with 5S / Visual Factory2. Builds a comprehensive Downtime Database by

cause, frequency, and duration3. Predicts and prevents downtime by PM system 4. Expands role of Operator as first point of early

warning and prevention5. Develops Professional Maintenance skills

TPM is a Lean tool to optimize the effectiveness of manufacturing equipment and tooling.

Slide 10

1

234567

Operator Autonomous Maintenance

Countermeasures for Contamination

Initial Standards

General Inspection

Autonomous Inspection

Standardization

Aut. Mgt.Seven Steps of TPM

7

6

5

4

3

2

1Initial Clean-up

Slide 11

TPM is Planned, Predictive, & Preventive

1. Starts with 5S / Visual Factory2. Builds a comprehensive downtime data

base by cause, frequency, and duration3. Predicts and prevents downtime by PM

system 4. Expands role of Operator as first point of

early warning and prevention5. Professional Maintenance

Slide 12

5S5S Workplace

SSortort (organize)SShinehine (clean) SSet in order et in order (make orderly and neat)SStandardizetandardize (visual place for everything)SSustainustain (maintain the system)

A safe, clean, orderly workplace is fundamental to quality, efficiency, and teams

Slide 13

TPM starts with 5S

• You can’t see problems clearly when the workplace is in disarray

• Cleaning and organizing the workplace helps the team to uncover problems

• Making problems visible is the first step of improvement

• Clean machines and workplace create pride & Safety

Slide 14

Downtime Visual Controls

• Visual or audio alerts – Abnormality obvious at a glance (e.g. stoppage,

reject, control fault)– Alerting Maint and team leaders– Provide real time “scoreboard” for employees

• Machine down light visible from aisle• Production status board (e.g. actual counts vs. goal)• Scrap counts and downtime minutes • Located in clear view in shop (not in control room)• Simple, self regulating, & employee managed

Slide 15

TPM is Planned, Predictive, & Preventive

1. Starts with 5S / Visual Factory2. Builds a comprehensive

downtime data base by cause, frequency, and duration

3. Predicts and prevents downtime by PM system

4. Expands role of Operator as first point of early warning and prevention

5. Professional Maintenance

Slide 16

Downtime Database

• Categorize at a minimum by Equip, Tooling, C/O, Other• Segmented bar graph for E-T-O lost time• Subcategories for Equip (e.g.)

– Hydraulic / pneumatic– Mechanical / lubrication– Electrical / controls– Shot-end components

• Subcategories for Tooling (e.g.)– Slides– Cores– Inserts– Ejector pins

• Subcategories for Other (e.g.)– Operator error– Materials

Slide 17

Minimum Downtime Tracking

0

20

40

60

80

100

120

Minutes

1Q02 2Q02 Jun Jul Aug Sep Oct Nov Dec

Downtime by Cause 3500 ton Bay(avg min/shift per Machine)

OTE

Equip

Tools

Other

Slide 18

TPM is Planned, Predictive, & Preventive

1. Starts with 5S / Visual Factory2. Builds a comprehensive downtime data

base by cause, frequency, and duration

3. Predicts and prevents downtime by PM system

4. Expands role of Operator as first point of early warning and prevention

5. Professional Maintenance

Slide 19

Predictive Maintenance Tools• Rate/hr vs. target or historical normal output (B/W)• Database

– MP2 / maintenance history– statistical probability (frequency & duration)

• Physical prediction of impending failure– Sound (bearing)– Temperature (cooling water)– Flash (core pins) – Shot monitoring system – SPC on part geometry – Hydraulic pressure (ejector pins)– Spindle loads (amps) – Fluids / Lubrication analysis (milipore)– Vibration Signature Analysis

Slide 20

Preventive Maintenance System• History of downtime by major machine & tool

– Downtime measurement & tracking– Mean Time Between Failures– Average downtime– Pareto of causes at component level (eg L/S or temp sensor)– Cost to maintain

• Develop PM cards based on frequency of failure and magnitude of average lost time (start small & grow)– Limit & prox switches– Shot tip / sleeve– Critical frame and cylinder mounting bolts– Expendable tools– Valves, hoses, packing, seals

• PM’s have instruction, schedule/frequency & sign-off – PM’s / repairs done in window of opportunity when machine is down– Cycle count or date based execution of PM’s (eg cutter change)– PM status visual (work completed / not completed)

Slide 21

TPM is Planned, Predictive, & Preventive

1. Starts with 5S / Visual Factory2. Builds a comprehensive downtime data base by

cause, frequency, and duration3. Predicts and prevents downtime by PM system

4. Expands role of Operator as first point of early warning and prevention• One point lessons for operator awareness• Creates OMP (Operator - Maintenance

Partnership)• Operator performs checks, problem

solving, and improvements5. Professional Maintenance

Slide 22

TPM

Production Operators• Clean & Check• Observe• Categorize

Manufacturing Engineers• Equipment Planning• Equipment Studies

Production Planning & Control

• Schedule P.M.

Quality Engineers• Standards &

Calibrations

ActivePlanned

MaintenanceProcess

Slide 23

OMP - Operator Maintenance Partnership

• Operator training in TPM• Operator basic equip inspection

& tooling checks• Operator basic cleaning• Operator lubrication check• One point lessons (capture

knowledge)• TPM Board & TPM Tags

(proactive operator involvement)

TPM

Slide 24

TPM Tag System

• Problem communication tool to and from maintenance, tool room, and production– Identify abnormal machine conditions

• Record problem discovered by operator• Record problem found during scheduled PM

– Status tracking system of requested repairs– TPM visual management tool (hang tags)– Repair history for future problem solving

• TPM Tag used for recording problem & fix– Blue Tag-Operator or Maint responsible to repair– Red Tag- Safety-related request (priority)

Slide 25

Operator/Supervisor Production Management Maintenance

1. Abnormality Identified

2. Fill out Tag Red= Safety Blue= Prod/Maint

3. Hang C-tag as close to the defect as possible

4. Hang A &B Tags on the TPM Tag status board by Machine location and area of responsibility to correct.

5.Maintenance evaluates problem. If fixed immediately go to 6. If parts or time needed, maint pulls A tag from board. The A tag is MWO. The B tag is posted on the Maint WO status section of the TPM Board with est. timing.

7. Operator/Supervisor check to see if work was done.

6.After work is completed, maintenance completes back side of A tag and places both the A & B tag in the work completed box

8. If OK, Operator/ supervisor removes C tag from machine and places ABC tags in Completed box. If not OK, tags stay and maint is contacted. Contact noted on tag.

9. Production management reviews the information. Also reviews the comments and takes actions if required. Places tag in history file box located in the office

Tag information is recorded and reviewed for continuous improvement of PM database by Production and Maintenance; Repeat operator tags may indicate Maint needs to investigate.

Tag Process

Slide 26

TPM is Proactive, Predictive, Preventive & Planned

1. Starts with 5S / Visual Factory2. Builds a comprehensive downtime data

base by cause, frequency, and duration3. Predicts and prevents downtime by PM

system 4. Expands role of Operator as first point

of early warning and prevention

5. Professional Maintenance

Slide 27

Professional Maintenance

• Equip Safety• Skill building• Cross-training• Area Maintenance• WC MRO stores• Maint Mgmt System• Down alarms• Radios • Planned PM

Slide 28

1

234567

Operator Autonomous Maintenance

Countermeasures for Contamination

Prepare Temporary Standards

General Inspection

Autonomous Inspection

Standardization

Aut. Mgt.

7 Steps

7

6

5

4

3

2

1Initial Clean-up

OIL

T P M

Slide 29

TPM

5S

TPM IStep 1Step 2Step 3

TPM IIStep 4 Step 5Step 6Step 7

Initial Focus

prerequisite for TPM I

Slide 30

STEP 3: Prepare Temporary Standards

This step is to enhance the equipment reliability & maintainability.• Temporary Check Sheet For Clean-Up, Lubrication, Start-up, and Shut-down:

– What items need to be done– Who will perform the check– How often to check– Where the location is to be checked– What to use for the inspection or cleaning– Target time to complete the task

Slide 31

TPM Summary

• TPM = Total Productive Maintenance– Proactive (all employees

involved)– Preventive– Predictive– Planned

• TPM is an integral part of JLF Total Quality production System

5S Visual Factory

T P MT P MStandardized

Work

Continuous Waste Reduction

Peak Performance

Slide 32

TPM is a Lean tool for Quality and Productivity