Professional Documents
Culture Documents
TPM
Overview
Slide 1
TPM as a Lean Initiative
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 Standardized
Visual TPM Work
Factory
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. Equipment breakdowns
2. Defects, scrap, and rework
3. Safety Issues
4. Mini stoppages
5. Reduced speed
Slide 8
What is TPM??
Slide 9
Operator Autonomous Maintenance
of TPM Standardization 66
Autonomous Inspection
55
General Inspection 44
Initial Standards
33
Countermeasures for Contamination
22
Initial Clean-up
11
Slide 10
TPM is Planned, Predictive, & Preventive
Slide 11
5S Workplace
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
Slide 13
Downtime Visual Controls
Slide 14
TPM is Planned, Predictive, & Preventive
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
Subcategories for Tooling (e.g.)
Slides
Cores
Inserts
Ejector pins
Subcategories for Other (e.g.)
Operator error
Materials
Slide 16
Minimum Downtime Tracking
120
Tools
100
80
O
Minutes 60
T
40 E
20
Equip
0
1Q02 2Q02 Jun Jul Aug Sep Oct Nov Dec
Slide 17
TPM is Planned, Predictive, & Preventive
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
Slide 21
TPM
Production Operators
Clean & Check
Observe
Categorize
Slide 22
OMP - Operator Maintenance Partnership
Slide 23
TPM Tag System
Slide 24
Tag Process
Operator/Supervisor Production Management Maintenance
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 5.Maintenance evaluates problem. If
status board by Machine location and fixed immediately go to 6. If parts or
area of responsibility to correct. 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.
Slide 25
TPM is Proactive, Predictive,
Preventive & Planned
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. 77
Standardization 66
Autonomous Inspection
55
OIL
General Inspection
44
Prepare Temporary Standards
33
Countermeasures for Contamination
22
Initial Clean-up
11
Slide 28
TPM
Initial Focus
TPM I TPM II
Step 1 Step 4
5S Step 2 Step 5
Step 3 Step 6
Step 7
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
Peak Performance
involved)
Preventive
Predictive Continuous Waste Reduction
Planned
TPM is an integral part 5S Standardized
of JLF Total Quality Visual TPM Work
Factory
production System
Slide 31
TPM is a Lean tool for
Quality and
Productivity
Slide 32