Total Productive Maintenance
TPM
Overview
Dave Hoyte, CEO JL French Corporation
Slide 1
TPM as a Lean Initiative Competitive costs require
Spending control Defect control Downtime reduction
TPM = Total Productive Maintenance
Proactive (with all employees involved) Preventive Predictive Planned
Slide 2
Why Change? ACTIONS:
Reduce defectives / scrap Reduction of lost production time Lowest possible cost by reducing waste
Slide 3
Lean System
Peak Performance Pull system / flow production Rapid Changeover / Customer-driven lot size Continuous Waste Reduction Lean Measures
5S
Visual Factory
TPM
Standardized Work
Variation reduction / Six Sigma In-Station Process Control Leadership by Example & Commitment Employee Involvement & Mutual Respect
Slide 4
7 Wastes
Transportation Excess production Added processes Motion
Waiting Inventory Non-conformance (defectives)
Slide 5
Causes of Waste
Excess Manning
Poor layout and material presentation Rework and extra processes Inconsistent / inefficient work methods
Excess Downtime
Tooling condition Unreliable equipment Long changeovers Incapable process
Defectives - Rework or Replace
Incapable processes or process not compatible with customer expectations or design spec (design for mfg) Tooling condition Operator methods and errors
Slide 6
Causes of Waste
Excess Manning
Poor layout and material presentation Rework and extra processes Inconsistent / inefficient work methods
Excess Downtime
Tooling condition Unreliable equipment Long changeovers Incapable process
Defectives - Rework or Replace
Incapable processes or process not compatible with customer expectations or design spec (design for mfg) Tooling condition Operator methods and errors
Slide 7
Effective TPM Eliminates 5 Losses
1. 2. 3. 4. 5.
Equipment breakdowns Defects, scrap, and rework Safety Issues Mini stoppages Reduced speed
Slide 8
What is TPM??
TPM is a Lean tool to optimize the effectiveness of manufacturing equipment and tooling.
1. Starts with 5S / Visual Factory 2. Builds a comprehensive Downtime Database by cause, frequency, and duration 3. Predicts and prevents downtime by PM system 4. Expands role of Operator as first point of early warning and prevention 5. Develops Professional Maintenance skills
Slide 9
Operator Autonomous Maintenance
Seven Steps of TPM
Aut. Mgt. Standardization Autonomous Inspection
7 7 6 6 5 5 4 4 3 3 2 2 1 1
Slide 10
General Inspection Initial Standards Countermeasures for Contamination Initial Clean-up
TPM is Planned, Predictive, & Preventive 1. Starts with 5S / Visual Factory 2. Builds a comprehensive downtime data base by cause, frequency, and duration 3. Predicts and prevents downtime by PM system 4. Expands role of Operator as first point of early warning and prevention 5. Professional Maintenance
Slide 11
5S Workplace
A safe, clean, orderly workplace is fundamental to quality, efficiency, and teams
Sort (organize) Shine (clean) Set in order (make orderly and neat) Standardize (visual place for everything) Sustain (maintain the system)
Slide 12
TPM starts with 5S You cant see problems clearly when the workplace is in disarray Cleaning and organizing the workplace helps the team to uncover problems Making problems visible is the first step of improvement Clean machines and workplace create pride & Safety
Slide 13
Downtime Visual Controls
Visual or audio alerts
Abnormality obvious at a glance (e.g. stoppage, reject, control fault) Alerting Maint and team leaders Provide real time scoreboard for employees
Machine down light visible from aisle Production status board (e.g. actual counts vs. goal) Scrap counts and downtime minutes Located in clear view in shop (not in control room) Simple, self regulating, & employee managed
Slide 14
TPM is Planned, Predictive, & Preventive 1. Starts with 5S / Visual Factory
2. Builds a comprehensive downtime data base by cause, frequency, and duration
3. Predicts and prevents downtime by PM system 4. Expands role of Operator as first point of early warning and prevention 5. Professional Maintenance
Slide 15
Downtime Database
Categorize at a minimum by Equip, Tooling, C/O, Other Segmented bar graph for E-T-O lost time Subcategories for Equip (e.g.)
Hydraulic / pneumatic Mechanical / lubrication Electrical / controls Shot-end components Slides Cores Inserts Ejector pins
Subcategories for Tooling (e.g.)
Subcategories for Other (e.g.)
Operator error Materials
Slide 16
Minimum Downtime Tracking
Downtime by Cause 3500 ton Bay (avg min/shift per Machine)
120 100 80 Minutes 60 40 O T E
Other Tools
Equip
20 0 1Q02 2Q02 Jun Jul Aug Sep Oct Nov Dec
Slide 17
TPM is Planned, Predictive, & Preventive 1. Starts with 5S / Visual Factory 2. Builds a comprehensive downtime data base by cause, frequency, and duration
3. Predicts and prevents downtime by PM system
4. Expands role of Operator as first point of early warning and prevention 5. Professional Maintenance
Slide 18
Predictive Maintenance Tools
Rate/hr vs. target or historical normal output (B/W) Database MP2 / maintenance history statistical probability (frequency & duration) Physical prediction of impending failure Sound (bearing) Temperature (cooling water) Flash (core pins) Shot monitoring system SPC on part geometry Hydraulic pressure (ejector pins) Spindle loads (amps) Fluids / Lubrication analysis (milipore) Vibration Signature Analysis
Slide 19
Preventive Maintenance System
History of downtime by major machine & tool Downtime measurement & tracking Mean Time Between Failures Average downtime Pareto of causes at component level (eg L/S or temp sensor) Cost to maintain Develop PM cards based on frequency of failure and magnitude of average lost time (start small & grow) Limit & prox switches Shot tip / sleeve Critical frame and cylinder mounting bolts Expendable tools Valves, hoses, packing, seals PMs have instruction, schedule/frequency & sign-off PMs / repairs done in window of opportunity when machine is down Cycle count or date based execution of PMs (eg cutter change) PM status visual (work completed / not completed)
Slide 20
TPM is Planned, Predictive, & Preventive
1. Starts with 5S / Visual Factory 2. Builds a comprehensive downtime data base by cause, frequency, and duration 3. Predicts and prevents downtime by PM system
4. Expands role of Operator as first point of early warning and prevention
One point lessons for operator awareness Creates OMP (Operator - Maintenance Partnership) Operator performs checks, problem solving, and improvements 5. Professional Maintenance
Slide 21
TPM
Production Operators Clean & Check Observe Categorize Production Planning & Control Schedule P.M.
Active Planned Maintenance Process
Manufacturing Engineers Equipment Planning Equipment Studies
Quality Engineers Standards & Calibrations
Slide 22
OMP - Operator Maintenance Partnership
Operator training in TPM TPM Operator basic equip inspection & tooling checks Operator basic cleaning Operator lubrication check One point lessons (capture knowledge) TPM Board & TPM Tags (proactive operator involvement)
Slide 23
TPM Tag System
Problem communication tool to and from maintenance, tool room, and production
TPM Tag used for recording problem & fix
Identify abnormal machine conditions Record problem discovered by operator Record problem found during scheduled PM Status tracking system of requested repairs TPM visual management tool (hang tags) Repair history for future problem solving
Blue Tag-Operator or Maint responsible to repair Red Tag- Safety-related request (priority)
Slide 24
Tag Process
Operator/Supervisor 1. Abnormality Identified 2. Fill out Tag Red= Safety Blue= Prod/Maint 3. Hang C-tag as close to the defect as possible 4. Hang A &B Tags on the TPM Tag status board by Machine location and area of responsibility to correct. 5.Maintenance evaluates problem. If fixed immediately go to 6. If parts or time needed, maint pulls A tag from board. The A tag is MWO. The B tag is posted on the Maint WO status section of the TPM Board with est. timing. 6.After work is completed, maintenance completes back side of A tag and places both the A & B tag in the work completed box 9. Production management reviews the information. Also reviews the comments and takes actions if required. Places tag in history file box located in the office Tag information is recorded and reviewed for continuous improvement of PM database by Production and Maintenance; Repeat operator tags may indicate Maint needs to investigate.
Slide 25
Production Management
Maintenance
7. Operator/Supervisor check to see if work was done.
8. If OK, Operator/ supervisor removes C tag from machine and places ABC tags in Completed box. If not OK, tags stay and maint is contacted. Contact noted on tag.
TPM is Proactive, Predictive, Preventive & Planned 1. Starts with 5S / Visual Factory 2. Builds a comprehensive downtime data base by cause, frequency, and duration 3. Predicts and prevents downtime by PM system 4. Expands role of Operator as first point of early warning and prevention
5. Professional Maintenance
Slide 26
Professional Maintenance
Equip Safety Skill building Cross-training Area Maintenance WC MRO stores Maint Mgmt System Down alarms Radios Planned PM
Slide 27
Operator Autonomous Maintenance 7 Steps
T P M
Aut. Mgt. Standardization Autonomous Inspection
7 7 6 6 5 5 4 4 3 3 2 2 1 1
Slide 28
OIL
General Inspection Prepare Temporary Standards Countermeasures for Contamination Initial Clean-up
TPM
Initial Focus
5S
TPM I Step 1 Step 2 Step 3
TPM II Step 4 Step 5 Step 6 Step 7
prerequisite for TPM I
Slide 29
STEP 3: Prepare Temporary Standards
This step is to enhance the equipment reliability & maintainability.
Temporary Check Sheet For Clean-Up, Lubrication, Start-up, and Shut-down:
What items need to be done Who will perform the check How often to check Where the location is to be checked What to use for the inspection or cleaning Target time to complete the task
Slide 30
TPM Summary
TPM = Total Productive Maintenance
Proactive (all employees involved) Preventive Predictive Planned
Peak Performance
Continuous Waste Reduction
TPM is an integral part of JLF Total Quality production System
5S
Visual Factory
TPM
Standardized Work
Slide 31
TPM is a Lean tool for Quality and Productivity
Slide 32
