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 can’t 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 • PM’s have instruction, schedule/frequency & sign-off – PM’s / repairs done in window of opportunity when machine is down – Cycle count or date based execution of PM’s (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

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