Understanding Full TPM Implementation

- An Executive Overview (36 slides)

Professor, University of Glasgow, UK

Skype contact moses.tan70 Email mosestc@gmail.com

2017 - ZenPower International, Singapore
 KEYs In TPM Implementation

(1) TPM Pillar Details & linkages

(2) TPM & the Maintenance Dept. Function
(3) Company Priority / resources

Zero BDs
Zero Defects
Highest OEE / Lowest Product Cost
(Zero-Loss / Ideal Cost)

Four Core Pillars

TPM's Three KEY Beliefs
1. Every breakdown and defect is due to a
deviation from the required Basic Machine
Conditions – Cleanliness, Lubrication, Proper
Bolting, Lifespan Inspection and Part Precision.
2. Every deviation is due to a Man- Mistake and
Man-Mistake
are preventable by Mistake-proofing (Poka-
Yoke).
3. Manufacturing Excellence is sustained by
building a CI Knowledge Bank to revise the PM
shut-down Job-list and shared to AM activities
activities..
3
How TPM Pillars Are Linked
Quality Focused
Planned Maintenance Improvement
Maintenance (Zero Defects ) (100% OEE)
( Zero BDs ) (Poka Yoke) (Cost Reduction)

Maintenance Knowledge bank

Autonomous
Enhanced PM
Maintenance
Joblist for
Pillar (eyes,
Maintenance
ears,hands
Department
helping Maint) 5
 TPM End-State Goals
From AM3: Initial Maintenance Standards (Knowledge-Bank)

Before::
Before After: New

“X” Shut-Down Revised “X” Autonomous

PM Job-List Shut-Down PM Maintenance
Job-list.

- All other Pillars contributions

- Improved OEE ( BD, Def ects.
ects...Jams,
Defects.
Setup, Speed, Startup and .Blade-
change losses) .
6
 PM Joblist
(AM3 Status) Sample Only

Model Current Current Items New items to Current PM NEW PM Job- AM3 final
Machine PM Job-list that Need be added to Job-list items list items recommended
Items Revision of Stds PM Job-list that are OK (Total QTY) list
FPP 36 items
FM 16 44 20 80 items 49 items
Bagging
Pac
k
NPP 22 items
GND 4 51 18 73 items 19 items
Cut
Extruder
AM Step-by-Step Audit Standards
Step # Step Goal Activity Pass-Standard.

Step 0 Prepare F-Tagging Map Grasp the current Machine F-Map (what/where)
Breakdown history

Step-1 Restoration Cleaning & Inspection => 85% repair rate

Step-2a Eliminate Sources of Kai

Kai’’zen improvements =>70% effective effort to
Contamination reduce Contamination.

Step-2b Improve Equipment Kai

Kai’’zen improvements =>70% effective effort to
Accessibility improve Accessibility.

Step-3 Initial Maintenance Stds. Equipment-knowledgeable =>50% reduced Sudden

operators. breakdowns.

Step-4 General Inspection Skills General check-up of => 90% reduced Sudden
Training & Implement equipment by operators. breakdowns.

Step- 5/
Step-5/ 6 Autonomous Inspection
5/6 AM/Pl Maint. responsibility => 95% reduced Sudden
optimized. breakdowns.

Step-7 Organize & manage Self Managing Work TBD.

workplace. Teams.

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 AM0 - Grasp Curent Status
AM0
�Prepared by Maintenance personnel.

� Systematize Defect and Breakdown knowledge in terms

of the 5 Basic Machine Conditions (BMCs)

� TPM believes that zero breakdowns and zero defect can

be achieved if the BMCs ( free of Contamination, correct
lubrication, correct bolting, correct inspection and correct
precision of machine functional parts) are strictly
controlled.

� Provides a starting baseline from which Step AM1

Activities for Continous Improvement is launched.
9
 F-Map Find Fuguai - Sample
Plan for AM1 Cleaning & Investigation Map
(For AM2a,2b - Eliminate Contamination & Improve Accessibility)
Team: Legacy Team

Assembly #1: Input Loader Assembly BMCs extracted from RCA BMC Gp List of Fuguai Restoration of Fuguai

Cannot load device into expansion track

BD1 BD1. Cannot load device into expansion track.
1a1 Loader stop pin damage. 3a FR None None
1a2 Worn-out expansion track 3c FR None None
1a3 Up/down reflective sensor loose connection. 1 FL None None
Left
2a 1a4 Bolts not properly tight that hold up/down reflective sensor. BR None None
1 2b 1a5 Bolts not properly tight that hold flag loader position lock pin. BR None None
Right 1a6 Worn-out loader pivot FR None None
1a7 Bolts not properly tight that hold insert loader pivot. BR None None
1a8 Bolts not properly tight that hold wheel singulator drive. BR None None

Fuguai discovered during F-Tagging BMC Gp

1b1 Bolt 6-32 Missing Completion
1b2 Gasket Damage Replaced
1b3 Lock washer 6-32 Missing Completion
1b4 Insert loader pivot 2b None None
1b5 bolts 6-32 loader pivot insert Wrong screw Replaced
Right 1b6 Pin loader pivot 2a None None
1b7 Loader base mounting 4b None None
3a 4a
1b8 Loader base 4a None None
4b 1b9 Flag loader stop pin 3b None None
1b10 Loader pivot spring Damage Replaced
3b 1b11 Miniature basic switch Damage terminal supply Replaced
Left 1b12 Button loader pivot worn out Replaced
3c 1b13 Spring clamp magazine worn out Replaced
Total: 8 Fuguais
Assembly # 2 : Storage Assembly BMCs extracted from RCA BMC Gp List of Fuguai

BMC = Basic Machine Conditions

 ( Step-1 : Restoration & Investigation )
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

11
 Find Contam & Access Sample
Plan for AM1 Cleaning & Investigation Map
(For AM2a,2b - Eliminate Contamination & Improve Accessibility)
Team: Bagging Team. Equipment: Bagging MC

Assembly #1: Bag Picking Assy
BMCs extracted from RCA
BD1.Bag Picking Assy cannot pick bag
to the roller printer.
BD#1a - Vac Cup Suction Low
1a1) Suction cup w orn/harden
1a2) Suction tubes loose/broke
1a3) Air filter clogged
1a4) Pump impeller broke
1a5) Pump motor burned
1a6) Pump bearing w orn
BD#1b - Vac Cup cannot reach Bags. * Affects a new filter performance
1b1) Cylinder leakage
1b2) Solenoid valve jammed
1b3) Air filter clogged
1b4) No w ater trap
Describe Contamination
1a3) Air filter clogged
* Water from air suppy IA.
* Collected on filter elements
* From Air Compressor.
w ithin 2 w eeks.
Accessibility problems
Contamination
1a3) Cleaning the air filter.
* No standing space to remove and
replace filter.
Other BMC Groups
1a4) Pump impeller
* Inside assembly cannot see.
1a5) Pump motor burned
* Inside assembly cannot see.
1a6) Pump bearing w orn
* Inside assembly cannot see.

Historical BMCs (not above)

Future BD Areas to be investigated:
1) Remove covers of gear assembly
housing and do a clean/tag of the belts,
gears and electrical contacts.
Bolts (fuguai/contam/Access)
Lubr (fuguai/contam/Access)
BMCs from Fuguai Found Describe Contamination Accessibility problems
Contamination
Tag 1-FR : Belts w ere w orn and Tag 3-Contam: Dust over elect Tag 3-Contam: Dust over elect
have play. w ires and joints. w ires and joints.
Tag 2-FR/Lubr : Gear Assy * dust from environment enter * Need to remove 8 screw s
movements noisy through vent gaps over time. to take out covers.
rustand no lubricant.

Tag 3-Contam: Dust over elect

w ires and joints.
 More Before & After Pictures
(Note: Need To Raise Maintenance Work Order For F-Tag Repairs)

Note - An AM1 Provisional Cleaning Std focusses on keeping an eye on the restored fuguais for sustainabilty.
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 ( Step-2a : Eliminate Sources Of Contamination )

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
14
implementation
5. AM2a Contamination
AM-2A CONTAMINATION ANALYSIS
Analysis Worksheet (3/5)
QUESTIONS ABOUT CONTAMINATION SOURCE ACTUAL FACTS COLLECTED SKETCH THE CONTAMINATION FALL-PATH
MACHINE: ASM5500 DURING INVESTIGATIONS

MACHINE SECTION: Waferhandler - Port1 1 What is it? Broken silicon pieces

2 Where is the source? Wafer protruding from Port1 Elevator cassette
3 How the contamination got there? (The Fall-Path) Not fully inserted because cassette was not seated
properly then smashed against lid housing upon
port initialise
CONTAMINATION TYPE: Broken wafer 4 Why is the contamination there? Wafer not fully inserted
5 When it get there? Upon impact with underside of lid housing

REFERENCE # : CONTAMINATION BASELINE BASELINE MEASUREMENT

a) HOW MUCH? ( volume, weight, count or an actual 1 broken wafer on 5 areas indicated
sample)
b) HOW LONG? - (Record the time for the Qty of 6 Months
CONTAMINATION EFFECT : contamination to accumulate)
Breakdown
Defect
Contaminate Lubrication
x General Area contamination
 AM2a Audit Standards (JIPM-Compliant)
7. JH AM2a Audit Standards & Results.
ARE A ELEMENTS M AX POOR GOOD EXCELLENT PTS COMMENTS FOR SCORE
BELOW M AXIM UM
1. Is the level of cleaning Evidence of Reasonable Excellent adherence
inspection started in Step 1 10 ineffective cleaning & im plem entation but and em bedded as part
SKILL UPGRADING

m aintained as a regular part inspection can do better of process

of the activities? 10
0 -3 4 -7 8 - 10
2. Is there evidence of training Little evidence of skill Majority are High levels of skill
and developm ent of 15 enhancem ent dem onstrating evident in the nos. of
m embers (visual controls, significant skills OPL’s and training
equipm ent functions, and
tools)? 0 -5 6 - 10 11-- 15
11 15
3. Are all participating in Low attendance Som e activity but High levels of
activities (attendance list)? Is 10 (<80%) and skill inadequate participation (>80%)
MA able to explain activities developm ent or developm ent and and MA are able to
& m/c functions? Is Team coordination attendance at <80% explain
Leader coordinating
activities? 0 -3 4 -7 8 - 10 10
4. Are sources of contam ination Som e inform ation but Som e activity but High levels of activity
TUS

summ arized into a list, 15 disorganized generally inadequate and progress

thoroughly analyzed and Need to add latest Breakdowns and
EQUIPMENT STA

effective counterm easures chronic defects in the Gap Analysis to

im plem ented? 0 -5 6 - 10 11-- 15
11 13 find more sources of Contamination.

5. Are the losses caused by A vague idea of Som e activity in place Very progressive, with
contamination quantified and 15 losses, and not but im provem ent to clear goals and results
counter-m easures to reduce quantified reduce contam ination are >70% reduction of
contamination by >70% is < 70% contamination.
effective? 0 -5
6 - 10 11
11-- 15 15
IMPRO VEMENT

6. Have m aintenance tasks Few if any Som e activities are in Skill levels are clear
been identified for transfer to 5 place but no plans and transfer plans in
operators? Is there a plan to place
upgrade skills? 0 -2 3 -4 5 5
7. Are the m ajority of “efu” Most “efu” are still Clear progress made Most “efu” are closed
S

closed or planned for 5 pending on “efu” elimination or with action plan

closure?
0 -2 3 -4 5 5

POTENTIAL SCORE 75 ACTU AL SCORE 73 Overall = 96.5%

 AM2a Benefit:
AM2a

� AM2a focus against the sources of

contamination and achieves => 70%
reduction of the contamination baseline.

� By reducing Contamination we reduce

machine breakdowns and product defects
and makes the machine and workplace
cleaner.
17
 ( Step 2b : Improve Equip Accessibility To Maintain ).

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 to
toclean
clean
Goes To
Step 4
Supervisor

Own
GM W/C Pre-Audit
Area
Audit Buy Off by TPM Dept
Buy Off 18 .
 AM 2b Benefit:
AM2b
� Many maintenance items are Time-
consuming and/or Hard-to-Access for
Cleaning, Lubrication, Bolting,
Inspection and Precision Checks.

� AM2b reduces accessibility time

by => 70% of the baseline time.

19
 AM3 Benefit:
�Based on "total fuguai" data, revise &
Improve and expand the PM Job-list

�Operators become all-present Eyes,

Ears, Hands For the accessible Sub-
set of updated PM Job-list for Cleaning,
inspection & precision checks.
20
 PM Joblist
(AM3 Status) Sample Only
Model Current Current Items New items to Current PM NEW PM Job- AM3 final
Machine PM Job-list that Need be added to Job-list items list items recommended
Items Revision of Stds PM Job-list that are OK (Total QTY) list
FPP 36 items 16 44 20 80 items 49 items
Bagging
NPP 22 items 4 51 18 73 items 19 items
Extruder
 C on tin u ou s Im p rovem en t W ork sh eet For U p d atin g PM S tan d ard s Job -list Item s
T oolset N am e:
P M item s
A ssy Inform ation source 2) P M D ecision
System ID - a) no change b)
D rive/E lect/Pnue/H d overall E arly W arning Signs M aint P arts (B D /D ef/F uguai/) Job-list revise stds c) add
y/W ater … .. function (M C or P roduct) R epaired/ R eplaced to PM list

B D #1 T ubes jam
1. B ase U nit To hold the M 70SW 11 u/s v A dd
L oader. tubes of
Assy 1-1) devices blocked drive v v R evise
Loader Input while Tubes are not m oving one D egraded proxim ity
stack waiting to by one sm oothly and som e switch v A dd
be loaded jam m in g are occuring.
into the battery valve u/s v A dd
m achine rot.drive jam , v NC
A M 2 C -m easures
access panel A dd

N ew F uguai O bserved during T agging… . W orn earth wire v A dd

B D #2 Tu b es can t
sh ift
A ssy 1-2 Tubes are not able to be
Loader Tube shifted one by one rot.drive jam , v A dd
sm oothly to the Loader proxim ity switch
shifter
Gripper. worn v A dd
tube tower dirty v v R evise
cylinder leak v A dd
singulator fingers
loose v A dd
22
tube stack height
loosen v A dd
 AM Operators becomes Maintenance Dept Dept’’s extra “ears,
eyes, hands, nose
nose”” to detect early signs of MC trouble and
thus helped to change Un-Planned Events into Planned
Events (Planned Maintenance)
 AM4 Benefit:
� Further improve/expand the PM
Joblist from successful OEE big losses
projects.

� Operators' scope increased, some

experienced operators can do line
maintenance.

24
M-Q (Machine-Quality) Summary after solving
"Thickness Fails" chronic defect.
Copper Brush, Flipper Spring
8
9 10 11 12 13

14
and Brass Bar.
5 4
1
7 6 3 2
Plating Chemical

Dryer Heater
Corner Spray and Rinsing Water
Dryer Blower

Part of Machine 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/l Lower => 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 �
O O O
Deterioration

Smoothness
 Checked by Prepared by Phenomenon Physical view (Logical reasoning)
Illegible or partial marking occurs during the marking The rubber pad does not transfer all the full characters from the stamp plate
PM Analysis Chart No 3/5
process at TM06. to the package surface resulting in Illegible Marking
4 M Correlation, 4M Correlation,
Contributing Condition Investigation Result Investigation Result Second Item Investigation/ Investigation Result If NG, Countermeasure Result
First Item
Temporary Temporary Measure - Restoration, Replace - Measurement
Investigation M easuring Measure - Investigation/ Measuring Temporary Measure - (3rd, 4th, 5th and 6th Measuring
Method
Decision ment Value
Decision
Method Decision Criterion ment Value
Decision
Items Decision ment Value Decision why NG? ment, Improvement, Value
Decision
Criterion Method Criterion Remodeling

3. INCOMPLETE
OR INSUFFICIENT
DEPTH OF 9 - 11 mils 7 mils NG 3.1 Deterioration 0.49 W - 0.46 W NG 0.50 W OK
CHARACTERS of laser Engraver 0.52W
ON STAMP PLATES. beam power
SIDE VIEW OF PLATE
SIDE VIEW OF PLATE Laser after power
deterioration
Actual
Laser

Characters not been

engraved deeply
caused illegible
marking. Characters not been
engraved deeply
caused illegible
marking.

2. Uneven stamp Even layer No method NG

plate layer. to measure

3. Residue ink on No ink residue Have ink NG 1. Not fully 1. To immerge 60 to 65 mm OK

used plate. in characters residue immerged in Stamp Plate into 75 mm
or stamp plate acetone after use. acetone properly.
2. Delayed to 2. Immediately maximum 15 min OK
immerge stamp immerge the plate 30 min
in acetone. after use. after
3. Stamp plate used
not cleaned
properly.
4. Acetone 4. To change the No No OK
container dirty. acetone 2x per week Illegible Illegible
marking. marking.
Design of Experiments During P-M Analysis For
Chronic Defects
OEE = Availability x Performance Rate x Quality Rate
OEE Waterfall Chart
Single-Dimensional chart (Less Useful)

1. Speed Loss
2. MTBA & Idling
OEE Loss Analysis Chart
Quantity Vs Time 2-D Chart (More Useful)

Speed Loss
(World class gap)

Speed Loss
(Company gap)

Availability
Loss

Quality Loss
MTBA & Idling
 frequently Process Improvements takes several
months during which unpredictable changes
in energy, materials, overhead costs, new process
problems. etc offset or hide the real cost reductions
achieve by them causing possible loss of motivation
Visit www.leantargetcosting for a software solution.

Source: JIPM 2014 Criteria.

 Using Costs To Drive C.I. Activities
Software uses Toyota Principles, TPM OEE, Lean 6S.

Principles of measuring ROI of Lean 6S How to plan X% Product Cost Reduction

and TPM OEE Projects - 1min 45s & link to CI, TPM, Lean 6S - 2min 46s

Watch on Youtube, Youku, Vimeo Watch on Youtube, Youku , Vimeo

https://www.youtube.com/watch?v=A-YG7K-E-d0 https://www.youtube.com/watch?v=c-
sqDNGmSGk&t=10s
Notes:
1. The Process Yield Project can reduce the Process Cost by 9.21% (Rank 1 ticked)
Note: Red numbers are Cost-Reductions adjusted to Baseline conditions to eliminate noise.
36