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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 Standardized
Visual TPM Work
Factory

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. Equipment breakdowns
2. Defects, scrap, and rework
3. Safety Issues
4. Mini stoppages
5. 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 Aut. Mgt. 77

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

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
Subcategories for Tooling (e.g.)
Slides
Cores
Inserts
Ejector pins
Subcategories for Other (e.g.)
Operator error
Materials
Slide 16
Minimum Downtime Tracking

Downtime by Cause 3500 ton Bay


Other (avg min/shift per Machine)

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

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 Active Quality Engineers


& Control Planned Standards &
Schedule P.M. Maintenance Calibrations
Process
Manufacturing Engineers
Equipment Planning
Equipment Studies

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
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
TPM Tag used for recording problem & fix
Blue Tag-Operator or Maint responsible to repair
Red Tag- Safety-related request (priority)

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.

7. Operator/Supervisor check to see 6.After work is completed,


if work was done. maintenance completes back side of
A tag and places both the A & B
tag in the work completed box

8. If OK, Operator/ supervisor 9. Production management reviews


removes C tag from machine and the information. Also reviews the
places ABC tags in Completed box. If comments and takes actions if
not OK, tags stay and maint is required. Places tag in history file box
contacted. Contact noted on tag. 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
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. 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

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
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