Operator Maintenance

Seven Steps To Success

Step
7 Autonomous Control
Step
6 Standardization
Step 5
Autonomous Inspection
S t ep
4 General Inspection
Step
3
Cleaning, Lube & Inspection Standards
Step 2
Eliminate Sources of Problems
Step
1
Hands-on Initial Cleaning
Operator TPM Checks
 Operator Maintenance

Seven Steps To Success

Step
7 Autonomous Control
Step
6 Standardization
Step 5
Autonomous Inspection
S t ep
4 General Inspection
Step
3
Cleaning, Lube & Inspection Standards
Step 2
Eliminate Sources of Problems
Step
1
Hands-on Initial Cleaning
Operator Maintenance

0 11 0 1 O 5 0
10 2
Before: 15 5 9
8
7 6 5
4
3 H L 20 10 15 5

10 M 15 10

5 10 01 2 M H 20 5 5 10
11 3
After: 0 15
10
9
8 7 6
5
4
L O 15 10 0 15
 TPM
 Everyone assumes a role in the total
maintenance system.
 Zero unplanned downtime is the GOAL.
 Accurate historical data on each piece of
equipment, including parts usage, downtime &
uptime and reason for downtime.
 Maintenance work-orders issued and
completed.
 Inventory of critical spare parts, cycle counting
& bar-coding.
Getting Started
HOW TO GET STARTED?

__________________________
__________________________
__________________________
__________________________
 Getting Started
 Decide pilot area that includes with some critical equipment .

 List and number all equipment and decide critical or non

critical. Develop list of PM’s for critical equipment.

 Decide what PM’s can the operators be trained to do and

develop a picture check sheet with description and
frequency for these TPM items
TPM Machine Numbering (example)
STANDARD M/C CODES
CUTTING PRINTING EMBROIDERY

M /C TYPE CODE M /C TYPE CODE M /C TYPE

SPREADERS CUT/SPRD/ 1of 5 PRINTING M/C PR/PR/ 1of 2 EMBROIDERY M/C
CUT/SPRD/ 2of 5 PR/PR/ 2of 2 THREAD REWINDING M/C
CUT/SPRD/ 3of 5 SAMPLE PRINT M/C PR/SAMP/ 1of 1 METAL DETECTOR
CUT/SPRD/ 4of 5 CURING M/C PR/CUR/ 1of 1 LASER CUTTER
CUT/SPRD/ 5of 5 HEAT SEAL M/C PR/HS/ 1of 2
CNC CUTTERS CUT/CNC/ 1of 2 PR/HS/ 2of 2
CUT/CNC/ 2of 2 LIGHT EXPOSE M/C PR/EXPO/ 1of 1
BAND KNIFE M/Cs CUT/BAND/ 1of 5 SCREEN DRYER PR/DRY/ 1of 1
CUT/BAND/ 2of 5 WATER PURIFYING M/C PR/WATER/1of 1
CUT/BAND/ 3of 5
CUT/BAND/ 4of 5
CUT/BAND/ 5of 5
MANUAL CUTTERS CUT/MAN/ 1of 8 FABRIC INSPECTION
CUT/MAN/ 2of 8
CUT/MAN/ 3of 8 M /C TYPE CODE
CUT/MAN/ 8of 8 FAB. INSP. M/C FI/INS/KNIT/1of 2
TUBULAR CUTTER CUT/TUB/ 1of 1 FI/INS/KNIT/2of 2
ROLL FORM CUTTER CUT/ROLL/ 1of 1 (LACE) FI/INS/WVN/1of 1
FUSING CUT/FUS/ 1of 2 (WOVEN) FI/INS/ LACE/1of 1
CUT/FUS/ 2 of 2 FAB. RELAX. M/C FI/REL/ 1of 2
SUB SEWING UNIT CUT/SEW/5TOL/1of 5 FI/REL/ 2of 2
CUT/SEW/4TOL/1of 3 MANUAL CUTTER FI/MAN/ 1of 1
CUT/SEW/SNLS/1of 4 PILLOW CASE SEW FI/WASH/4TOL/1of 2
CUT/SEW/3NCS/1of 2 FI/WASH/4TOL/2of 2
STEAM IRONS CUT/SEW/IRON/1of 3 SAMPLE FAB. CUTTER FI/SAMPLE/CUT/1of 2
CUT/SEW/IRON/2of 3 FI/SAMPLE/CUT/2of 2
CUT/SEW/IRON/3of 3
TPM Standard Work (example)

Spreader Maintence Schedule

1,2,5,7
3 4
8

Date
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16
Maintenance Schedule for Operator Fre que nc y

ĵLï a#z sh Ë_ìì a#ñq? Da ily

yNõ@Y k#D a#ñ w#N a#ñq? Da ily

yNõ@Y a`r:kup`AgÎc#rØváy`krûq? Da ily

ÎyÉw wWWcyt c`_ Ôdny a#ñq? Da ily

 Getting Started
 Develop a autonomous TPM tag that operator fills out a request to
maintenance to fix what can be fixed later by maintenance. Of course if it
needs fixed immediately get maintenance now.

 Develop a TPM board where a tag is place for request for repair and the
maintenance can return the tag when the repair is complete.

 This completes the autonomous system between the operator and

maintenance person that will handle small issues at their level without
management intervention
 But visible enough so management can assure the system is working.
 TPM Tag (example)
ndWó
Request¿Þm s>h` iLÅm
for maintenance @q~;y
Repair Îv#rØ ¿Þm

Øny:……………………………………..
Date Date
Øny:……………………………………..

Time
@ìl`c:………………………………….. Time
@ìl`c:…………………………………..

M/c number
yNõ@Y # Corrective
Îv#rØ Action
¿Þmt gW áy`m`Rgy:

……………………………………. …………………………………………………

…………………………………………………
Problem
@q~;y:………………………………………

…………………………………………………. ………………………………………………

……………………………………
Name©LÓy`@G
k`RÉk of the nm:
Mechanic
Operator’s
yNõ æy`kr#@Gname
nm:
………………………………………………… …………………………………………………
 TPM Visual Board(example)

Machine Machine Machine Machine Machine Machine

1 2 3 4 5 6

Machine Machine Machine Machine Machine Machine

7 8 9 10 11 12

Machine Machine Machine Machine Machine Machine

13 14 15 16 17 18
TPM Implementation Plan(example)

Lean Implementation Plan - Activeline

OBJECTIVE Total Productive Maintenance

Project Champion Samitha

Project Goals Indicator 1

Current State
Future State (Feb. 07)
Plan Act

Complete
Project Initiatives Date

TPS review meeting action points

Complete
Mtg Date Action Lead Responsibility Date
9/28 To conduct a PDCA training for TPM team Shri 10/4 10-5 at 10.00 am
9/28 To displays b/d records of m/C in charts/c type wise weekly) Rohana 10/4
9/28 Compile a list of the m/c of all departments Thiwanka 10/4 Done
9/28 Deicide the critical m/c Thiwanka/Samitha 10/4 Done
9/28 Establishing the m/c coding system Rohana 10/4 Done
Numbering
9/28of all m/c(Nalin/Waruna,Suranka/Kapila,Rohana/Dhammike,Samitha,Rohan/Dumindu,Suranka/Himal)
All 10/4
9/28 Develop check list for cutting m/c Nalin/Samitha/Chaminda 10/6
9/28 Decide the Training of operators on TPM by next meeting Shri/Chaminda 10/4
9/28 To do the tagging board with spreaders Samitha/Chaminda 10/4 Done
9/28 To show the things to check list Chaminda 10/4 Done
9/28 To do the tagging training for both shifts(Operators & mechanics) Thiwanka/Samitha 10/5
9/28 Brief process owners on the tagging boards Shri 10/4
10/4 Monitoring Fabric inspection m/C down time from wekk 40 onwards Rohana 10/4
 Getting Started
 Although the TPM system is in place,
maintenance should capture and analyze
what items need improved in regards to
PM’s or if TPM is not reducing unplanned
down time, its check items are not effective
and need to be revised / improved.