ZenPower International

Industry TPM Consultants

Moses Tan (MSc, BIT), is the Principal TPM
Consultant of his own Consultancy Company,
ZenPower International, since 1996. He was
formerly TPM manager of a TDK company for
6 years. His clients include Local, Western,
Japanese MNCs in the IC Assembly, Test &
Plating, SMT, Materials, Auto parts industries.
Website: www.tpmquality.com
tpm/moses 1
 TPM OVERVIEW
Manufacturing & Administrative Excellence.

tpm/moses 2
 Background of TPM
• Main manufacturing excellence approach of Toyota and
other excellent Japanese companies since the 70’s.
• TPM is foundation for JIT, FA, Poka Yoke, Lean
Manufacturing, Zero Defects.
• TPM Reference Standard - JIPM (Japan Institute of Plant
Maintenance)
• Comes from the best of Japanese Industrial Excellence and
evolved from the heat of the continuing Energy Crisis and
Globalization challenges to achieve More with Less.

tpm/moses 3
 TPM GOALS
1. Increase asset Utilization and Equipment OEE
2. Foster Production Equipment Ownership
3. Equipment breakdown prevention ( Planned
Maintenance through CM, TBM, CBM)
4. Defect Prevention (QM Process & Poka Yoke )
5. Evolving into Self Directed Work Teams
(SDWTs) and Lean Manufacturing.

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JIPM STANDARDS
1. TPM Structure & Organization
2. Equipment Improvement activities
3. Production Autonomous Maintenance
4. Planned Maintenance
5. Quality Maintenance
6. Product & Equipment Initial Control
7. Education & Training
8. Office TPM
9. Safety, Hygiene & Environment
10. Quantifiable TPM Measurement
tpm/moses 5
 Executive Overview Of
1. Autonomous Maintenance
2. Equipment Improvement
3. Planned Maintenance
4. Quality Maintenance
5. Office TPM
tpm/moses 6
QUICK LOOK AT

Production
Autonomous
Maintenance
tpm/moses 7
 LOGIC OF AM STEPS
STEP 7
STEPS 4,5,6 FLATTENED
IMPROVE WORKER ORGANIZATI
KNOW-HOW TO MAINTAIN ON.
EQUIPMENT THROUGH
STRUCTURED SPECIFIC
SKILLS.
STEPS 1,2,3
IMPROVE THE
EQUIPMENT
USER -
FRIENDLINESS

tpm/moses 8
 AM STANDARDS
Step # Step Goal Standards
Step 1 Restoration => 85% repair rate
Step 2 Eliminate Sources of Contamination =>70% successful effort
Step 3 Improve Equipment Accessibility =>70% successful effort

Step 4 Initial Maintenance Standards

> 50% sudden b/d reduction

Step 5 General Inspection Skills > 90% sudden b/d reduction

Step 6 Autonomous Inspection > 95% sudden b/d reduction

Step 7 Organise and manage workplace TBD by management

tpm/moses 9
 ( Step-1 : Restoration Equipment )
LEADER

OPERATORS

MAINTENANCE
STAFF

SUPERVISORS
GROUP LEADER ENGINEERING
MEETING TO STAFF COUNTER CONFIRMATION
LIST OF EXT/INT
DEPT.CHIEF PLAN COUNTER MEASURES OF PROGRESS
ABNORMALITIES
MEASURES

AUTONOMOUS
MAINTENANCE STEP-1 AUDIT
ENGR. GROUP MODEL MACHINE
STAFF
MAINT.
STAFF

LEADER

SUPERVISORS

COUNTERMEASURES
TO NEXT STEP FOLLOW UP ON AUDIT
AUDIT EXTENDED TO ALL
FEEDBACK
EQUIPMENT

DEPT.CHIEF

tpm/moses 10
 ( Step-2 : Eliminate Contamination & Stains on Area & Parts)
What ?

Complete Step-1 AM Team

Where ?
Step-1 Summary => 70%
Countermeasures
results & findings How
much

Why ?

Step-3
1st Pre-
Audit
by TPM
Dept.

Present
GM/Sponsors Countermeasures Own area
Audit to TPM WC and Buy - Off
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implementation 11
 ( STEP 3 : IMPROVE EQUIPMENT ACCESSIBILITY ).

AM Leader
Inaccessible
Model m/c Areas difficult or
Passed inaccessible for cleaning No Place To
Step 2 checking & lubricating Stand
Wiring or piping Product Manager
obstruct
Cannot see
easily
Time Operator Leader/ Operators
TimeConsuming
Consuming
Model Machine totoclean
clean
Goes To
Step 4
Supervisor

Own
GM W/C Pre-Audit
Area
Audit Buy Off Dept.
tpm/moses Buy Off by TPM 12
 ( Step 4 : Initial Maintenance Standards )

Hard to
Model m/c Initial lubricate
passed maintenance Hard to check AM Leader
Step 3 standard oil level Product Manager
Abnormality
in lubrication Operator
Abnormality
equipment Leader/operator
in circulation
of lubrication Draft standards Counter measure for
Equipment for cleaning, cleaning and checking
gets dirty inspection &
Supervisor
during oiling lubrication
Engineer & Maintenance
Confirm
standard for Attach
cleaning, identification Trial Period
inspect & label
lubrication
Proliferation
of Step 4
TPM dept. tpm/moses 13
Pre-audit GM audit
 ( Step 5 : General Inspection skills )

•Lubrication
•Lubrication select
selectgeneral
general Prepare
Preparetexts
textsand
anddaily
daily
•Equipment
•Equipmentparts
partstightening
tightening inspection
inspectionitems
items schedules/check
schedules/checklists
lists
•Pneumatics
•Pneumatics
•Hydraulics
•Hydraulics
•Electrical Manuals
Manuals Managers/supervisors
Managers/supervisors
•Electrical
•Drive participate
participateinintraining
training
•DriveSystem
System Checklist
•Water
•Water Cut
Cutaway
away
•Fire
•Fireprevention/safety
prevention/safety models
models Test
Test
Revised
Revised
Maintenance
Maintenance
standards
standards Implement
general Im..

Proliferate GM TPM
GMAudit
Audit TPMoffice
office
Step-5 Pre-Audit
tpm/moses
Pre-Audit14
 ( Step-6 : Autonomous Inspection )

Maintenance Inspection standards,breakdown analysis

Operators
Step-5 Revise provisional standards who
understand
Step1
Step1to
to3:
3: Step-4
Step-4 their
equipment
Establish
Establishbasic
basic Daily
Dailychecking,
checking, (able
conditions
conditions adjustment,and
adjustment,and to maintain
(cleaning
(cleaningand
and improvement
improvementof of
lubrication) conditions inspection
lubrication) conditionsfor
for
correct
correctoperation
operation standards)

Inspection skill check-up

Finalise standards for cleaning
tpm/mosesand lubrication 15
 Step-7 : Organise and Manage Workplace

Organise and set standards for :

EQUIPMENT PRECISION
INSPECTION ITEMS

TOOLS AND MATERIALS

STANDARDS FOR FLOW AND STORAGE
INDIVIDUAL WORK
RESPONSIBILITIES
tpm/moses 16
QUICK LOOK AT

Planned
Maintenance
Pillar
tpm/moses 17
GOAL OF PLANNED
MAINTENANCE.
Achieve “ZERO EQUIPMENT BREAKDOWNS”
by implementing systems of
“parts replacement before failure” through
TBM and CBM.
EQUIPMENT TOTAL MAINTENANCE
STANDARDS
PRODUCTION P.M. STANDARDS
AUTONOMOUS GENERAL INSPECTION
MAINTENANCE SYSTEM. STDS.
+

tpm/moses
ANNUAL MAINTENANCE 18
PLANS
PLANNED MAINTENANCE
ACTIVITIES:
O SUPPORT AUTONOMOUS MAINTENANCE ACTIVITIES BY
TECHNICAL SUPPORT, BREAKDOWN ANALYSIS AND
DEMARCATION BETWEEN PRODUCTION & P.M. SYSTEMS.
O P-M ANALYSIS FOR CHRONIC BREAKDOWNS.
O TIME BASED MAINTENANCE ITEMS
O CONDITION BASED MAINTENANCE ITEMS.

O SPARES MGTM & MAINTENANCE DAY PRACTICE.

tpm/moses 19
 QUICK LOOK AT

Equipment
Improvement
Pillar
tpm/moses 20
 ROLE OF PLANT EI TEAM
Achieve systematic breakthroughs in
equipments’ 6 BIG LOSSES and establish
Standards for Basic Machine Conditions.

The Basic Machine Conditions are:

1. Cleaning Standards.
2. Lubrication Standards.
3. Bolt-tightening Standards.

tpm/moses 21
EQUIPMENT 6 BIG LOSSES
(FOCUS IS AT THE BOTTLENECK
PROCESSES.)
1. BREAKDOWN LOSSES
2. SPEED LOSSES.
3. SETUP LOSSES.
4. DEFECT LOSSES.
5. START-UP OR YIELD LOSSES
6. MINOR STOPPAGES LOSSES
tpm/moses 22
 SEVERITY OF EQUIPMENT 6 BIG LOSSES

LOSSES
LEVEL 1 LEVEL 2 LEVEL 3
MAINT
Maint
LEVEL 1 LEVEL 4
LEVEL
• Have chronic B/Ds • Only spontaneous • Time-based component maint. • Condition-based maint
1.Breakdown • B/d Repair time PM time. breakdowns. system. system
• >20% deviation of • B/d Repair time = PM time. • D/Trepair time < PM time • Maint staff do only PM.
service life range. • Within parts service life • B/d downtime < 1% • AM do D/T repairs < at 0.1%
losses • Root-cause s of breakdown span. • Service life of components of DT level.
not clear. • Root-causes of B/Ds are => upper range of specs. • Clear improvement
clear and addressed. in MTBF
• Incomplete setup • Complete set-up • Successful efforts to convert • Optimal set-ups under 10
2.Setup documentation. documentation on-line to off-line setups mins.
• Setup times variation • On-line and off-line setups • All adjustments are fully • 1st time set-up produce good
Losses >30%. are defined. clarified and standardized. parts. No need to adjust any
• SetupTime variation < 15% further.
3.Minor •. REDUCED 1/20TH OF
• No awareness/data. • Data on frequency, location Root-causes
•CURRENT LRVRL.of minor • Zero minor stoppages.
Stoppages of minor stoppages. stoppages are clear and
countermeasures in place.
• Equipment specs not clear. • Root-causes are clear • Countermeasures for root- • Operates at designed speed or
4.Speed • No settings documented by • Settings documented by causes of speed losses above.
Losses different packages/ package / machine type. implemented. • Zero Speed losses
machine models & types. • < 5% variation between same • Revised settings with notes on
type machines quality and accuracy impact.
• < 2% speed loss.
• Nothing done about • Chronic defects are • Countermeasures implemented • M-Q relationship established.
5. Defect & chronic losses. quantified by type, frequency effective for early in-process • Regular audit of Q-
Startup
Losses • No results from previous and volume. detection of defects. components
actions • Root causes for problems are • Q-components identified and • Loss due to quality defects is
identified and understood. effects on quality are clear. < 0.1%

tpm/moses 23
OVERALL EQUIPMENT EFFICIENCY

OEE => 85% target

NOTE: OEE IS NOT THE SAME AS
UTILIZATION. UTILIZATION MEASURES THE
UP-TIME OF THE EQUIPMENT. OEE
MEASURES THE ‘ABILITY’ OF THE
EQUIPMENT TO PRODUCE. LIKE THE HORSE-
POWER RATING OF AN ENGINE, OEE
DESCRIBES THE EQUIPMENT’S HEALTH.

tpm/moses 24
Sporadic & Chronic Problems
Why-Why P-M Analysis.
Analysis.

FOR PROBLEMS
WITH CLEAR AND
ASSIGNABLE
CAUSES. FOR PROBLEMS WITH
CLEAR CAUSES & NO
EFFECTIVE COUNTER-
MEASURES
tpm/moses 25
Why-Why Analysis & P-M Analysis
• Used with other data analysis or data collection
tools.
• Emphasize on logical reasoning to fully
understand the whole chain of cause-effects so as
to devise holistic multiple solutions.
• All defects, breakdowns, accidents and work –
problems are result of an error by Man which is
the Root Cause.
• Problems are traced to all the 4Ms
• Solution Sustained by linked to the TPM systems.
tpm/moses 26
 Checked by Pre pa re d by Phenomenon Physical view (Logical reasoning)
Hook ing errors occasionally occur during Distance b etween the roller at the tip of the flyer and hook needle cha
PM Analysis Chart No1/3 continuous winding during hooking
Contrib uting 4 M Correlation, 4M Cor relat ion ,
Investigation Result Investigation Result Second I t em
Investigation Result C ountermeasure Res
Condition First Item Investigation/ If NG,
T em por ary T em por ary ( 3r d, 4t h, 5th T em por ary Rest orat ion , Replace -
In vesti gat ion Me a s ure - m e nt I nv est igati on/ Measuri ng Measure - Measuring Measure - why NG? Measur em ent
Decision D eci sio n Decision D eci sio n and 6 th It ems Decision D eci sio n m ent, Im pr ovem ent ,
Measu rin g Met ho d Value Meth od men t Value men t Value Value
Cr it erio n Cr it erio n Method Cr it erio n Remodel ing

1. Po sitio n at wh ich 1 70º to 180 º 1 06º to 180 º NG 1- 1 Flyer rotatio n is 1to 1 5kg /cm² 20 kg /cm² NG 1- 1-1 . T ensi on Gauge 120g to 1 50g 170g to 3 00g NG Car bon powders Clean 12 0g t o 15 0g
ro lle r a tip of no t smoo th when lo ad Car bon co nt act co nt act fr om a depo sit
flye r s to p s is no t ap plied. p res sur e of t he sur face i nsi de brush box .
c ha ng es . slide r ing is hi gh . ·Spr ing di ff erent Replace with 14 0g
fr om th ose in o ther t he sam e spr ing
1 80° places was us ed.
(1/ 8 pl ace)
90° 2 70° car bon slide r ing
1- 1- 2 Gallin g of To uch by h and Sm o o th with Smo o th OK

0° spin dle beari ng. n o ro ug h ne ss

1- 1-3 . V-belt P ush-p ull gauge A mo un t o f A d ju s tme nt wa s m ad e b y ·Adjus t am oun t o f belt 10 mm /1kg cm
ten sio n is hi gh . d ef el c tio n 2 to 3 mm / t urn ing th e b elt a nd defl ect ion .
1 0 m m/1 k g c m² 1 k g c m² NG to uc h ni g it b y ha nd .

1- 1- 4. Mo tor Thick ness gauge 0 . 1 to 0 .3 m m 0 . 1 to 0 .6 m m N G ·P la te s p ring o f ·Replace 0.2 5mm

brak e pad b ra ke dis c d a ma ge d

clear ance

1- 1- 5 Mo tor Thick ness gauge 0 . 1 to 0 .3 m m 1. 0.2 5mm OK

clutch plat e 2 . 0. 3mm OK
clearan ci ng of 3 . 0.3 mm OK
br ake disc
damaged.

1- 1-6 . Dial gauge Be ol w 0 . 0 5 0.0 3mm OK

Spin dle shaft
def lectio n

tpm/moses 27
QUICK LOOK AT

Quality
Maintenance
Pillar
tpm/moses 28
 QUALITY
MAINTENANCE:
IS ACTIVITIES TO SET EQUIPMENT CONDITIONS,
BASED ON THE BASIC CONCEPT OF MAINTAINING
PERFECT EQUIPMENT TO MAINTAIN PERFECT
QUALITY OF PROCESSED GOODS. THE MACHINE
CONDITIONS (Q-COMPONENTS) ARE CHECKED AND
MEASURED IN TIME-SERIES TO VERIFY THAT
MEASURED VALUES ARE WITHIN STANDARD
VALUES TO PREVENT DEFECTS. THE TRANSITION OF
MEASURED VALUES IS WATCHED TO PREDICT
tpm/moses
POSSIBILITIES OF DEFECTS OCCURRING AND TO 29
TAKE COUNTERMEASURES BEFOREHAND
 ROLE OF PLANT TPM-QM
Achieve “ZERO DEFECT” by identifying all the
upstream factors of Equipment causes of defects
and implementing fool-proofing techniques to
eliminate man and materials-caused defects.

1. Identify all the Q-components

2. Implement fool-proofing techniques to
prevent man and materials-caused defects.
3. Eliminate all Chronic defects.

tpm/moses 30
 Copper Brush, Flipper Spring
9 10 11 12 13 and Brass Bar.
8
14

5 4
7 6 3 2 1
Plating Chemical

Dryer Heater
Corner Spray and Rinsing Water
Dryer Blower

Part of M achine Plating Chemical Flipper B. Bar / C. Brush Dryer Heater

Measurement Chemical Content Tension Contact Pressure Hot Air Temperature

Std. Value MSA: 37.5% +/- 5% Upper <= 250 g Upper = 6 kg/cm Upper = 130 deg. C
TIN: 37.5 g/l +/- 5 g/l Nominal = 120g Nominal = 5.5 kg/cm Nominal = 125 deg C
Additive: 2 g/l +/- 0.5 g/lLower => 60g Lower = 5 kg/cm Lower => 120 deg C

Interval Daily Weekly Forthnightly Daily

Quality Defect
Thickness Fail Thickness Fail Thickness Fail Thickness Fail
Quality of M /c Part

Circularity

Content
EXAMPLE OF AN M-Q
Deterioration (MACHINE-QUALITY) MATRIX
Smoothness
Q-Tag number & Revision Q-tag # 60-001 Rev A
tpm/moses
Q-tag # 60-002 Rev A Q-tag # 60-003 Rev A
31
Q-tag # 60-004 Rev A
 ABOUT OFFICE TPM
• Is a structured 5S program using Why-Why
Analysis as a problem-solving tool.
• Has similar Autonomous Maintenance 5 Steps
• Improves “CRITICAL FUNCTIONS” of
Ware-house, Storage Place, administrative
areas’ through work-flow studies.
• Areas contributing to OEE losses are selected
for Kai’zen activities.
tpm/moses 32
The 5S step-by-step program.
1 - Cleaning & Restoration. THOROUGHLY RESTORE & CLEAN.
MOTIVATION THROUGH
PARTICIPATION.
2 - Eliminate Stains, Mixed, STUDY ROOT CAUSES OF DIRT,
Contamination. MIXING,
LOSS, DAMAGE AND TAKE ACTIONS.
3 - Improve Accessibility. ACHIEVE 1 MINUTE ACCESSIBILITY
TIME FOR DOCUMENTS + PARTS.
IMPLEMENT STOCK-MANAGEMENT-
4 – Standardization & AT 1 GLANCE.
ACHIEVE A PROBLEM-FREE WORK
Control of Work. FLOW IN STOCK INVENTORY, DATA
AVAILABILITY.
5 - Self Management SELF MANAGING WORK TEAMS.
tpm/moses 33
 TOGETHER......
Towards World-Class Manufacturing Excellence

TPM JIPM,

tpm/moses 34
 TPM MASTERPLAN 2001 - 2003
DEVELOPMENT DESCRIPTION INTRODUCTORY STAGE PRACTICE STAGE CONSOLIDATION STAGE FINAL STAGE
PROGRAM 2001 2002 2003 2004 JIPM AWARD
Policy Basic Objective Proliferation and total involvement Defects and breakdowns prevention Zero defects and zero breakdowns through every employees’ involvement Challenge the standards

Basic TPM
Weekly WC mtgs
Organisation & Regular EI mtgs

Main Committees Regular PM mtgs

Select Model machine, form Teams, Implement improvements on Model M/Cs & then proliferate to all similiar equipments to achieve a skilled workforce and equipment that do not breakdown.
Basic Strategy

Policy
Employee
Suggestion Scheme Pilot Area

for Continous {Tech. Opr Standards}

Proliferate
Step 5 : General Inspection Skills
Imporvement 5.1 Bolts, Nuts, Lubrication
5.2 Pnuematics
OEE/ Breakdowns/ Quality 5.3 Electricity & Motors
TPM Measurements
Step 1 1 Rest of M/cs 5.4 Oil Hydraulics
Pilot M/cs 2 5.5 Participate in in-line repairs
Step 1: Restoration
Autonomous Step 2 Step 3 3
Step 2: Eliminate Contamination • Technical Operators
Maintenance Step 3 : Improve Accessibility Step 4 4
• OEE => 85%
Step 4 : Initial Standards Step 5 5
(5 Pilot Lines then manuals 6
-Prepare Inspection manuals Step 6
85% of rest of types Step 5 : General Inspection manuals Step 7 7
of equipment) Step 6 : Autonomous Inspection
Step 7 : Manage quality of work

Technical support for AM (Lubrication & bolting)

Eqipment Baseline current m/c losses
Improvements Model m/c basic conditions
Model m/c losses improvements
on 6 losses
Implement
Establish systems & schedules
Planned maintenance schedules
PM & QM (Time & condition based) Implement
Analysis Control Standards Quality matrixes
Systems Machine/Prodcut Quality matrix

AM Skills workshops
TPM Training and PM Analysis workshops Establish Implement
Skills Advanced workshops
Development
Develop Implement on test run
Develop trouble prevention
Early Equipment & checklists on
Product Control
Review Enhance
5S Program for office
Office TPM
Review Enhance

Safety, Hygiene &

Equipment Safety tpm/moses 35
Workplace environment & waste
Environment treatment
 THANK
YOU
tpm/moses 36