TPM COACHES COURSE

IPA & LTA

What is IPA?

I dentify P rioritise A ssign

Identify the Assign the

projects that Prioritise the prioritised
need to be identified projects to
done to projects the right
improve the resource
KPI

...is a methodology that cascades the objectives into

projects applicable only with quantitative measures

TPM/FI – IPA & LTA 3 v1.4

 Why do we need it ?

Operational Projects Operations

Master Plan Scoping Review

Helps to enhance
your Operational
Master Planning Can be used in the
Helps to break a operations review in
(OMP) in order to
larger scoped DMAIC order to identify new
reach our
projects into many projects if the results
objectives...
smaller DMAIC are not achieved In
(Top-Down Approach)
projects. Full and On Time..
(Bottom-Up
Approach)
Source: IPA Training Material
TPM/FI – IPA & LTA 5 v1.4
Summary of Goals and Outputs for
IDENTIFICATION of Projects

Goal
 Ensure that the projects identified
will improve the KPI.

 Make sure that the projects are

going to reach the objectives by
setting specific targets.

Output
 List of potential projects that will
reach the KPI target.

3 Projects identified:
• Project in Line 6 in department A in the factory A
• Project in Line 2 in department A in the factory A
• Project in Line 1 in department A in the factory A

TPM/FI – IPA & LTA 6 v1.4

Summary of Goals and Outputs for
PRIORITISATION of Projects

Goal
 Ensure that the projects • Discuss the weighting with unit management team
identified will be based on • Use prioritisation matrix
prioritisation criteria. • Use the project classification tool

 Ensure visibility on the projects

that will deliver high impact to
the business results

Output
 List of prioritised projects to
ensure the achievement of KPI
target
.

TPM/FI – IPA & LTA 7 v1.4

Summary of Goals and Outputs for
ASSIGNMENT of Projects

Project Coach Project Sponsor

Goal
 Ensure that the projects identified
and prioritised will be given to
appropriate resources that have the
right level of competence and
knowledge to perform the projects.
Project Leaders
 Ensure visibility on the training
needs.

Output BEFORE AFTER

 List of prioritised projects with clear

DMAIC Overview DMAIC Overview
4 4

Roadmap 3 Define Roadmap 3 Define

2 2

roles and responsibilities of the StoryBoard

1

0 Measure StoryBoard
1

0 Measure

resources available within the unit Control Analyse Control Analyse

(Ex: DMAIC and SMED - project leader, project Desired Level

Improve
Initial Situation Desired Level
Improve
Current Situation Initial Situation

coach and project sponsor defined)

TPM/FI – IPA & LTA 8 v1.4

Deployment at the factory/unit level
Building competence in IPA methodology
The ownership of execution of IPA is transferred from the FI Pillar to the Executive
Committee, then to the Local Committee (up to the Sub local committee, if applicable).

FI Pillar Leader
(Technical)

FI Pillar Leader Executive committee =

(factory) Factory/unit management team

Local committee =
Department/area management
FI Pillar team
Members Local committee =
Department/area management
team
Local committee =
Department/area management
team
TPM/FI – IPA & LTA 9 v1.4
Loss Tree Analysis assists in accelerating cost reductions
through improved prioritisation

Loss Tree is a methodology of the FI Pillar for identifying and

prioritising losses based on the financial impact to the factory

Think of your line as a tree from which you are

losing money which you would like to harvest

Losses
Visible

Apply problem Apply problem

solving solving
Line methodology methodology
Hidden

Losses reduce
Loss Tree Root causes emerge
Root causes
Root causes unknown Losses reduce
become clear

TPM/FI – IPA & LTA 10 v1.4

Loss Tree raises zero loss awareness, prioritises losses and
feeds into the factory strategy

What are the benefits of Loss Tree?

Mindset and engagement Valuation and prioritisation
• Forms part of NCE • Turns qualitative measures into
• Creates belief in zero-loss
quantitative loss ($)
awareness in all employees • Prioritises losses by financial value,
• Visual representation of losses for
Safety, Health and Environmental
all to see Significant Losses, problem solving
• Transfers the ownership of losses
tools and TPM maturity.
from managment to the shop floor • Supports AM, PM, ET , SH&E & Quality
pillars by linking losses to pillar activities
Strategic planning
• Provides an overview of Losses for the
Zero Loss Journey and
Operational Master Plan
• Training plans created based on
losses and TPM maturity

TPM/FI – IPA & LTA 11 v1.4

To ensure everybody moves in the same direction is
important to have a common understanding of waste

One of the main aims

of Loss Tree is to raise
awareness of waste

But what does Loss

Tree consider as
waste?
Now with extra inventory – just in case!

Lets look at an example Waste is anything taking place which

from the Nestlé world does not deliver value to the
consumer or transform the product

TPM/FI – IPA & LTA 12 v1.4

There are eleven ‘machine’ categories with eight mandatory
sub-categories which support TPM

Idle
Idle Time
Time
Unoccupied
Unoccupied
Legal
Legal Restrictions
Restrictions
Machine Planned
Planned Maintenance
Maintenance
Breakdown Trial
Trial
Breakdown
Start
Start up
up of
of new
new product
product
Process
Process Failure
Failure
Start
Start up
up of
of new
new equipment
equipment
Minor
Minor Stoppages
Stoppages
Meals/
Meals/ Breaks
Breaks
Trials
Trials and
and Initial
Initial Start
Start up
up
Training
Training
Speed
Speed Losses
Losses
Meetings
Meetings
Organisational
Organisational Losses
Losses
Changeover
Changeover
Set
Set up,
up, Shut-down
Shut-down and
and Adjustment
Adjustment
Routine
Routine start-up/shut-down
start-up/shut-down
Rework
Rework and
and Waste
Waste
Planned
Planned cleaning
cleaning
Machine
Machine or
or Process
Process waiting
waiting Operational
Operational downtime
downtime
Mandatory Recommended Factory defined
TPM/FI – IPA & LTA 13 v1.4
There are five “Material” and “Man” losses with
fourteen sub-categories

Overfill
Overfill
Material Waste
Waste
Material Losses
Losses
Rework
Rework
Material Technical
Technical spare
spare parts
parts Packing
Packing Material
Material
Material
Material Destroyed
Destroyed
Utilities
Utilities Losses
Losses
Yield
Yield or
or Process/
Process/ Quality
Quality Loss
Loss
Energy/Steam/Env.
Energy/Steam/Env. Losses
Losses

Absenteeism
Absenteeism Sickness
Sickness
Accidents
Accidents
Man Additional
Additional Time
Time Industrial
Industrial disputes
disputes
Unplanned
Unplanned leaves
leaves
Each loss category may have several
sub-categories for additional detail Meetings
Meetings
Some sub-categories are mandatory,
Training
Training
others recommended
Line
Line Inefficiency
Inefficiency
Factories can define as many sub-
categories as they wish Rework
Rework Processing
Processing
Mandatory Recommended Factory defined
TPM/FI – IPA & LTA 14 v1.4
The ownership of execution of LTA is transferred from the FI
Pillar to the LC then the AWGs

Knowledge to FI Knowledge to Knowledge to

Pillar (pilot line) Local Committees AWGs (step 5 AM)

FI LC 2
AWG 1
FI Pillar
Leader Pillar
FI Member
Coach

FI Member
Coach
FI Member LC 1
Coach
AWG 2

FI Member
Coach

FI Member
FI Member 3 LC reps in AWG
FI Member Coach
Coach Coach
train and lead Loss
2 FI pillar reps in LCs Tree on their line

train and lead Loss Tree

1 Market FI pillar leader train on the lines in their area More details in Module 4
Factory FI pillar on pilot line
TPM/FI – IPA & LTA 15 v1.4
To ensure a consistent way of working a seven step
methodology has been defined for Loss Tree

Communication and CI
7. Consolidate Publish and communicate Loss Tree
6. Collect and loss tree at Main input to project selection
Quantify area and
Man Data factory level
Step Objective
1. Build One team with 100% people
engagement by developing a common
5. Collect and Wait for vision and goal to achieve Zero waste
Quantify next Loss
2. Develop practical skills needed to
Material Data Tree
1. Build zero loss
review build Loss Tree in the FI pillar/ EC/ LCs
awareness in Factory and AWGs (dependent on maturity)
Management and FI
Pillar Start on one line to create a learning
environment to develop skills and
2. Build LTA capabilities to support expansion
4. Collect and capability and
Quantify ownership in 3. Ensure data is correct for the Loss
Machine Data Loss Tree Tree so that decisions are made based
owners on reliable data.
3. Data
reliability
4-6.Build up the Loss Tree by assigning
assessment data to the categories
7. Consolidate the information from the
lines at local and executive levels

TPM/FI – IPA & LTA 16 v1.4

Before starting to build the Loss Tree it is important to check
the reliability of your data

Data
Data reliability
reliability check:
check:

It
It is
is important
important that
that you
you know
know what
what margin
margin of
of error
error you
you have
have
in
in your
your data
data
You
You can
can do
do this
this as
as you
you are
are collecting
collecting your
your data
data

Machine
Machine data
data reliability
reliability check:
check:

•• Investigate
Investigate your
your SAM
SAM unexplained
unexplained minutes
minutes
•• Compare
Compare your
your AMM
AMM data
data entries
entries with
with your
your SAM
SAM entries
entries
•• Compare
Compare your
your SAM
SAM idle
idle time
time with
with your
your SAP
SAP idle
idle time
time

TPM/FI – IPA & LTA 17 v1.4

 Each loss category is assigned to an accountable pillar whom
it is FIs job to coach and assist

Loss
Loss Categories
Categories Resp.
Resp. Accountable
Accountable Support
Support
Unoccupied
Unoccupied LEAN
LEAN V.
V. S.
S.
Planned
Planned Maintenance
Maintenance AM
AM // FI/
FI/ SHE
SHE
Machine PM
PM
Breakdown
Breakdown AM
AM // FI
FI // SHE
SHE
Process
Process Failure
Failure FI
FI AM
AM /ET/PM
/ET/PM // LEAN
LEAN V.S./
V.S./ SHE
SHE
Minor
Minor Stoppages
Stoppages AM
AM FI
FI // PM
PM // SHE
SHE
Trials
Trials and
and Initial
Initial Start
Start up
up EM
EM Quality
Quality // AM
AM // PM
PM // SHE
SHE

Committee
Local Committee
Speed
Speed Losses
Losses FI
FI AM
AM // PM/QP
PM/QP /SHE
/SHE LEAN
LEAN V.S.
V.S.
Organisational
Organisational Losses
Losses FI
FI PM
PM // Quality
Quality // SHE
SHE //AM
AM // LEAN
LEAN V.S.
V.S.
Machine
Machine or
or Process
Process Waiting
Waiting LEAN
LEAN V.
V. S.
S. FI
FI // PM
PM // Quality
Quality // SHE
SHE // AM
AM // ET
ET
Set Local
Set up,
up, Shut-down
Shut-down and
and Adjustment
Adjustment FI
FI AM
AM // PM
PM // Quality
Quality // ET
ET // LEAN
LEAN V.S.
V.S.
Rework
Rework and
and Waste
Waste Quality
Quality FI/PM/AM/SHE/
FI/PM/AM/SHE/ LEAN
LEAN V.S.
V.S.
Material
Material loss
loss FI
FI PM
PM // Quality
Quality // SHE
SHE //AM
AM // LEAN
LEAN V.S.
V.S.
Technical
Technical spare
spare parts
parts PM
PM FI
FI // AM
AM
Material
Utilities
Utilities loss
loss SHE
SHE FI
FI // PM
PM // AM
AM // LEAN
LEAN V.
V. S.
S.
Absenteeism
Absenteeism SHE
SHE FI
FI // AM
AM // ET
ET
Additional
Additional Time
Time LEAN
LEAN V.
V. S.
S. FI
FI //AM
AM // ET
ET // Lean
Lean Office
Office // SHE
SHE
Man

TPM/FI – IPA & LTA 18 v1.4

This slide shows the link between TPM phase and
the losses
TPM
TPM FI
FI Pillar
Pillar Losses
Losses to
to tackle
tackle
Maturity
Maturity step
step
55 Sustain
Sustain 00 Loss
Loss Unoccupied
Process
Unoccupied
Process
Organisational
Organisational Losses
Losses
Phase
Phase 22 44 Focus
Focus on
on high
high
complexity Absenteeism
Absenteeism
complexity
losses Machine
losses Machine or
or Process
Process waiting
waiting
Planned
Planned Maintenance
Maintenance
Technical
Technical spare
spare parts
parts
33 Focus
This
This is
is aa
Phase
Phase 11 Focus on
on low
low Trials
and
and medium
medium
Trials and
and initial
initial start
start up
up recommendation
recommendation of of
complexity
complexity Additional
Additional Time
Time when
when youyou should
should
losses
losses
Material
Material Loss
Loss start
start tackling
tackling losses,
losses,
Process
based
based upon
upon the
the
Process Failure
Failure
maturity
maturity level
level of
of the
the
22 Strengthen
Strengthen & Utilities
Utilities Losses
Losses factory
accelerate
& factory
accelerate ability
ability
to
to solve
solve low
low
complexity
complexity
Breakdown
Breakdown
Phase
Phase 00 losses
losses Set
Set up,
up, Shut-down
Shut-down and
andAdjustment
Adjustment
Speed
Speed Losses
Losses
11 Evaluate
Evaluate and
and
understand
understand the
the Rework
Rework and
and Waste
Waste
current
current situation
situation
Minor
Minor Stoppages
Stoppages

TPM/FI – IPA & LTA 19 v1.4

The ET pillar uses Loss Tree to establish a training plan as most
losses can be linked to a skills gap

6. Evaluate the activities 1. Analyze the current

and plan for the future. 6 1 situation and define
strategic priorities and E&T
policy.

5. Foster an environment that

5 E&T 2 2. Understand the actual
encourages self-learning. competencies, connect
the gaps to the business
4 3 needs and prioritize E&T
deliveries.
4. Design a skill- 3. Develop and delivery
development program for training solutions and
all employees, including the right competences
the new comers. for trainers.

TPM/FI – IPA & LTA 20 v1.4

 Project Selection Process

Different GA FI LEAN
Sources of Potential Escalated
Loss Tree Value Stream
Improvement Projects issues from Others
Reviews Analysis Design

Operational
Master Project Selection Tool
Outputs: Planning
Including Scoping
• Top priority projects selected aligned & Prioritisation (from FI)
with strategic goals (OMP + IPA)
• Project methodology defined (GSTD,
DMAIC levels, SMED, TPM and LEAN
Project DMAIC Trainings

Selection
Advanced DMAIC

tools) and project leader assigned with Intermediate DMAIC

Knowledge

Sponsor
Basic DMAIC 2

the appropriate competence

Process
Basic DMAIC 1

Go-See Think-Do

Time
• Trainings needs identified and fed into
the factory capability building plan
• Integrated into Technical division/
Factories resource capacity planning
(Project Leader, Project Coach and Project
Sponsor)
Source: FI Reference Guide
TPM/FI – IPA & LTA 21 v1.4
 FI Project Selection Process Details
Yearly Process with Quarterly Reviews

I P A
15.Calculate the
1.Receivethe target 8.Do we
11.Do we projects results until
from Function for all have enough
KPIs have end of the year +1
projects to
reach resources
2.Analyse historical data available and
Placeholder target ? Yes trained
(unit level, 12 months)
? Yes 16.Are we
achieving our
No objectives for
3.Look at assumptions, No
forecast, opportunities, year +1
?
variability for each KPI
12.Use the skill matrix Yes
and plan trainings No
4.Finalise understanding according to it
of current situation 17.Identify the gap to
9.Prioritise all the close
13.Train people
5.Seta target for each projects identified (for
sub-unit according to all KPIs)
current situation 14.Assign the 18.Go back to step 6
10.Classify according resources to all the and follow the same
6.Identify the main to complexity of cause projects prioritised process
contributor to the KPI & project scope
results (for each KPI)

19.Finalise your
7.Drilldown to the OMP
project level (using
pareto)
Source: FI Reference Guide

TPM/FI – IPA & LTA 22 v1.4

 Required DMAIC Knowledge Depends on Project Scope
and Expected Complexity of Causes
Manufacturing – Generic approach

Scope of Project
Complexity of One production
qualitative analysis tool

More than one More than one

Causes One piece of line or several Several lines or
area or whole factory or the
equipment pieces of one area
factory supply chain
equipment
1. Causes not known:
Identified through
brainstorming or why- Basic 1
why analysis Go-See Think-Do Basic 1 Intermediate Intermediate
or SMED

2. Causes not known:

Analyse process
variation and identify
mixed

causes Intermediate to
Basic 1 Basic 2 Basic 2 Intermediate
Simple statistics advanced

3. Causes not known:

quantitative

Analyse process
variation and identify
causes Intermediate to
Basic 2 Intermediate Intermediate Advanced
Complex statistics advanced

Note: This classification is indicative and a project can be classified differently depending on the context (e.g.: cross areas/Markets involvement
in the Project, might increase its complexity). The final classification needs to be validated by the FI Pillar leader and process owner according
to their experience.

TPM/FI – IPA & LTA 23 v1.4