TPM Awareness

TPM - FI Implementation 1
 Eight pillars of TPM
TPM

Autonomous Maintenance

Focused Improvement
Planned Maintenance

Quality Maintenance

Initial Control
Office TPM
Education and Training
Safety, Health and Environmental Management
TPM - FI Implementation 2
How FI fits with the other TPM pillars

Planned Maintenance

Quality Maintenance

Safety, Health &

Initial Control

Environment
Office TPM
Focused Improvement

Autonomous Maintenance

Training and Education

(in operating and maintenance skills)

TPM - FI Implementation 3
 Loss structure and major losses

9 2

3
10

5
11

6
12

7
13

15

14

16

Cost related
Manpower related Equipment related
TPM - FI Implementation 4
 Loss structure and major losses (contd.)

Rev. 1 dt 15/11/2010 TPM - FI Implementation 5

 Loss structure and major losses (contd.)
1. Breakdown loss : Machine, Mold, Die and work holding device

2. Set-up and adjustment loss : Mold, Die and Work holding device

3. Minor stoppages : Machine, Mold and Die

4. Reduced speed : Cutting speed and feed, Mold and Die movement, etc.

5. Defects loss : Rejection at in-house, Rejection at Customer end, Rejection at

Supplier end

6. Rework loss : Rework at in-house, customer end and supplier end

7. Start-up loss : Preheating of Mold, Die, Furnace – Metal temperature rise

8. Yield loss : Process and Design

TPM - FI Implementation 6
 Relationship between losses and OEE

Loading
time

Operating
time

Net
operating
time

Valuable
operating
time

TPM - FI Implementation 7
 TPM Targets

TPM targets are

P Achieve 85% OEE minimum

Reduce breakdown
Q Zero customer complaints
Reduce in-house rejection
C Reduce production cost
D 100% delivery service level
Zero line stoppages
S Zero accident
Zero first aid incidence
M Increase kaizens per employee
TPM - FI Implementation 8
 Purpose of TPM
Improve the company by improving its people and its equipment

---- Develop people with the skills required for today’s highly
automated factories ----
Improving People
1. Operators : Do AM
2. Maintenance staff : Do advanced, specialised maintenance
3. Production engineers : Plan maintenance-free equipment

+
1. Raise OEEs by improving the equipment currently in use
Improving Plant
2. Design new equipment for minimum life-cycle cost and
Equipment
vertical start-up

Culture Change
TPM - FI Implementation 9
 Definition of TPM (Company-wide TPM)
TPM is defined as a programme that:

1. Aims to create a culture and environment that constantly tries to maximise the
effectiveness of the entire production system

2. Uses a hands-on-approach to build a “Zero Accident, Zero Defect, Zero

Breakdown” system designed to prevent losses of all types throughout the
life cycle of the production system

3. Includes development, sales, administrative and other departments as well as

production

4. Involves everyone at every level of the organisation, from top management to

front-line employees

5. Uses over-lapping small-group activities to attain the target of zero losses

TPM - FI Implementation 10
Focused Improvement (FI)
Implementation

TPM - FI Implementation 11
 Contents

 What is FI?

 What are Losses?

 FI system

 7-steps procedure of FI

TPM - FI Implementation 12
 What is Focused Improvement?

 Set the target Loss and Eliminate loss step by step

 Repeat Improvements until all causes of loss can be eliminated

 Focused Improvement = Project

TPM - FI Implementation 13
 What are Losses?

Ideal condition / situation

 Identify Losses
GAP = Loss
 Tackle the Losses (eliminate)
(Obstructive Factor)  Prevent the Losses

Current Condition /
Situation

What Losses are identified in TPM?

TPM - FI Implementation 14
 FI system
Type Focus Difficulty Implemented by

Rank A Project team

Profit-seeking Rank B Maintenance

Eliminate losses
Budget
appropriated per
project Rank C Operators

Rank A Project team

AM back-up Eliminate
Budget contamination
sources and Rank B Maintenance
appropriated as
improve
lump sum accessibility
Rank C Operators

TPM - FI Implementation 15
 Criteria for Assessing Difficulty
Rank Assessment Criteria
A 1. Losses and problems arising in many departments
2. Major sources of spills and leaks neglected for many years
3. Serious, urgent problems causing significant customer complaints, late
deliveries, etc
4. Complex problems requiring advanced technical expertise
5. Costs estimated at over xx
B 1. Losses and problems limited to a single department; contamination sources of
intermediate severity
2. Corrections to equipment weaknesses such as strength, construction, materials,
etc
3. Improvements requiring an intermediate level of technical expertise and
estimated to cost between xx to xx
C 1. Losses that operators can eliminate with appropriate devices and guidance
2. Improvements to awkward situations hindering routine operation, checking,
lubricating, etc
3. Eliminating contamination sources nor requiring major equipment modifications

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 7-step procedures for FI
Step Description
1. Set topic and targets Decide on the improvement topics, based on assessment of the current situation
Decide responsibility for tackling each losses
Use zero-loss thinking to set targets and schedule
2. Draw up a plan Draw up an action plan, showing the schedule for analysing the problems, devising and
implementing the countermeasures
Have the plan reviewed by cross-functional project team and top management
3. Analyse problem and Use all available analysis, studies, experiments, and other techniques, together with
propose improvements experienced engineering knowledge, to formulate and evaluate improvement proposals
Work up each proposal to the point where it is virtually certain the targets will be attained
Present the proposal to top management and make any final alterations.
4. Implement Obtain the necessary funds
improvements Implement the proposed improvements

5. Check results Check how far each loss has been reduced since implementing the improvements
If the benefits turn out to be insufficient, go back to step 3 and review the situation
6. Lock down Make any technical modifications required to ensure that the improvements stay locked in
improvements place
Establish the necessary operating and maintenance standards
Provide operators the training required to ensure the same problems do not occur
Carry out a top management review
7. Roll out to other areas Roll out the improvements to similar lines, processes and equipment
(HD) Choose the next line and start the next round of improvements

TPM - FI Implementation 17