Beruflich Dokumente
Kultur Dokumente
Overview of TPM
Overview 2
Overview of TPM
1950s
Preventive maintenance
1960s
Production maintenance
TPM in production department (Manufacturing industry) Companywide TPM (whole industry) Global TPM TPM in unmanned operation plants
Overview of TPM
Overview of TPM
1. Taking as a prime objective a company structure that pursues production efficiency to its ultimate limits. ( = Comprehensive efficiency) 2. Putting together a practical shop-floor system to prevent losses before they occur throughout the entire production systems life cycle: Zero accidents, Zero Defects, Zero Breakdown etc. 3. Involving all functions, including production, Development, Sales and Management. 4. Having all employees participate from top executives to front-line workers 5. Achieving Zero losses through overlapping small groups.
Overview 5
Overview of TPM
Overview of TPM
Daily Prevention
Preventive Maintenance
Overview 7
Individual Improvement
Planned Maintenance
Development Management
TPM
Equipment Ownership
Quality Maintenance
Office TPM
Overview of TPM
Overview of TPM
Overview of TPM
Individual Improvement
Purpose: Realize zero losses of all types, such as failure losses and defect losses Demonstrate ultimate production efficiency improvement Members: Staff Line Leader Activities: Understanding the 16 major losses Calculating and settling goals for overall equipment efficiency, productivity and production subsidiary resources Implementation of PM analysis Thorough pursuit of equipment and production as it should be.
Overview 10
Overview of TPM
Equipment Ownership
Purpose: Training of operators proficient in equipment Protecting ones own equipment by ones staff Members: Operator, Line Leader Activities: Implementation of 7 steps 1. Initial clean-up 2. Countermeasures for the source of problems and measures for difficult-toaccess locations 3. Creation of tentative Equipment Ownership standards 4. General inspection 5. Autonomous inspection 6. Standardization 7. All-out goals management
Overview 11
Overview of TPM
Planned Maintenance
Purpose: Improving efficiency of maintenance departments to prevent 8 major losses Members: Staff Leader and maintenance men of maintenance department Activities: Daily Maintenance Time Based Maintenance Condition Based Maintenance Improvement for increasing the service life expectancy Control of replacement parts Failure analysis and prevention of recurrence. Lubrication control
Overview 12
Overview of TPM
Quality Maintenance
Purpose: Achieve zero defects by supporting and maintaining equipment conditions Members: Quality assurance Staff, Production engineering staff, Line Group Manager Activities: Verify quality characteristics standards; understand defect phenomena and performance Investigating the conditions for building in quality, unit processes and raw materials, equipment and methods Investigating, analysing and improving the conditions of malfunctions Setting 3M conditions; setting standard values for inspection Creation of standards that can be followed; trend management
Overview 13
Overview of TPM
Development Management
Purpose: Reducing product development and prototyping time Reducing the development, design and fabrication time of equipment Improving 1-shot start-up stability of products and equipment Members: Research and development staff, Production engineering staff, Maintenance staff Activities: Setting development and design goals Ease of production Ease of QA Implementation Reflect in MP design Ease of use Ease of maintenance Reliability Investigate LCC Design release drawing Production: Identify problems in the prototype, trial run and initial-phase mass production control stages.
Overview 14
Overview of TPM
Office TPM
Purpose: Achieve zero function losses Creation of efficient offices Implementation of service support functions for production departments Members: Leaders and members of administration/Indirect departments Activities:
Equipment Ownership activities 1. Initial clean-up (personal space) 2. Work inventory 3. Countermeasure for problems 4. Standardization 5. Promotion of autonomous management activities of work Individual improvement through project activities 1. Shortening of settlement schedule 2. Improvement of distribution 3. Improvement of purchasing and subcontracting 4. Reform of production control system
Overview 15
Overview of TPM
Overview of TPM
Overview of TPM
7. Establishing systems for improving production efficiency 7.1 7.2 7.3 7.4 8. 9. 10. 11. Steady application 12. Individual improvement Equipment Ownership Planned maintenance
Operation and maintenance skills upgrading training
Pursuing maximum efficiency of production Project team activities and small group activities in the workshop Step system, diagnosis and qualification certification Improvement maintenance, periodic maintenance, predictive maintenance Group education of leaders and training members Development of easy-to-manufacture products and easy-tooperate equipment Setting conditions without defectives, and its maintenance and control Support for production, increasing efficiency in the department and of equipment Establishing zero accidents and zero pollution systems Application of PM award Challenge of a higher target Overview 18
Establishing initial control systems for new products and equipment Establishing quality maintenance organization Establishing systems to improve efficiency of administration and other indirect departments Establishing systems to control safety, sanitation and working environments Total application of TPM and raising its level
Overview of TPM
Overview of TPM
KAIZEN
Kaizen Levels Restoration Betterment Kaizen Revolution Renovation
-Aim at achieving what the equipment and the operation must be in the future.
Renovating Kaizen
KK -20
Overview of TPM
Overview of TPM
KK -22
Overview of TPM
Overview of TPM
Overview of TPM
Overview of TPM
Overview of TPM
KK -27
Overview of TPM
KK -28
Overview of TPM
KK -29
Overview of TPM
Relationship between Six Major Losses on Equipment and Overall Equipment Effectiveness
Equipment Loading time Down time losses Operating time Net operating time Valuable operating time
Six major losses
Calculation of overall equipment effectiveness
Availability = (e.g) loadingtime downtime loadingtime 460mins 60mins. 460mins. 100
c d
Availability =
100 = 87%
Performanc e theoretical cycle time x processedamount = 100 efficiency Operatingtime (e.g) Performanc e 0.5mins./unit x 400units = 100 = 50% efficiency 400mins
Speed losses
Defect losses
g h
Rate of quality processedamount - defect amount = 100 = 100 products processedamount (e.g) Rate of quality 400 units - 8 units = 100 = 98% products 400 units
Overview of TPM
Loss by suspension
Loss by stoppage
(T/H) Performanc e = Actualaverageproduction 100% efficiency Standardproduction (T/H) Performanc e = (D)100 % efficiency (C)
Loss by capacity
Loss by deficiency
( (T ) ) Rateof quality =Production(T) 100% products Production(T) Rateof quality= (E) 100 % products (D)
Reprocessing
OPE= Availability x Performance x Rate of Quality pro ducts efficiency
KK -31
Overview of TPM
Overview of TPM
Step
Step 4
Details
Plan improvements
Activity
1. Make improvement proposals and prepare drawings 2. Compare cost effectiveness of alternate proposals and make budget 3. Check for possible adverse effects and disadvantages
Step 5
Implement improvements
1. Carryout improvement plan 2. Perform tests, trial runs 3. Provide instructions to work on improved equipment, operating conditions.
Step 6
Check results
1. Evaluate results with time as improvement project goes on 2. Check whether targets have been achieved, if not start from step 3 again
Step 7
Consolidate gains
1. Prepare inspection and work standards 2. Make drawings and feed information to Development management Pillar 3. Train operators and or fitters to sustain the results
KK -33
Overview of TPM
KK -34
Overview of TPM
Overview of TPM
Overview of TPM
Hinshitsu-Hozen
What is Hinshitsu-Hozen? To maintain integrity of quality (state of 100% non-defectives) * Condition setting : Set conditions for zero defects aimed at equipment and processes that do not produce quality defects. Daily and periodical inspections : Inspect and measure conditions in time series. Quality preventive maintenance : Prevent quality defects by maintaining measured values within the standard Trend control and predictive maintenance : Predict possibilities of quality defects occurring by observing trends of measured values. Prior countermeasures: Take measures beforehand
* * *
JIPM, 1994
QM - 37
Overview of TPM
shortening of inspection time Drafting of QM (Quality Maintenance) matrix and reflection in standards
QM - 38
Overview of TPM
Overview of TPM
QM Master plan
Master Plan for quality maintenance is planning of various activities in this pillar with respect to the time frame in months and years. According to the stage of TPM implementation it can start at various levels. In the beginning it will start with data collection on defects to improving conditions to sustaining zero defect conditions.
QM - 40
Overview of TPM
QM - 41
Overview of TPM
3M analysis
This analysis is a set of conditions with respect to machine, material and method for obtaining a good products. It helps in identifying 3M standards and checking is possible against these standards. Removing this variability can some times eliminate Quality Defects in the product.
QM - 42
Overview of TPM
Both sheet should be seated Hand without gap Uniform Rotation 24010 V No jerking Visual
Comp.sup.
Daily
Prodn.sup
dipper agitator Drying All teat end heaters should be switched off in I drier Visual Prod.Sup. Daily
QM - 43
Overview of TPM
3M Condition
Required value
Responsibility
No.1 product weight 0.75 - 0.80 Gms. Material(LATEX) S.I.Value Total alkalinity Sediments 2.0 - 2.4 0.35 - 0.50 % No sediments
Weighment Prodn.sup
QM - 44
Overview of TPM
Voltage variation
3 4
Overview of TPM
Required value
Exactly on viton ring No gap No play Uniform stripping No worn out layers
How to check
ResponsiFrequency bility
Supervisor Operator Operator Operator Operator Every shift Twice in a shift Twice in a shift Twice in a shift Once in hour
What to do
Visual Visual
1200/900V +100V Voltmeter Electrician No powder LEDshould glow. No product in helmet Visual Visual Visual Fitter Electician Operator
Overview of TPM
Overview of TPM
People always make mistakes. These can be reduced or even eliminated. Some of the Poke-Yoke devices, which can help avoid defects, are ; Guide Pins / Locators of different sizes. Error Detection Buzzers and Alarms Limit Switches, Proximity and Photosensors. Counters Checklists
QM - 48
Overview of TPM
QM - 49
Overview of TPM
QM - 50
Overview of TPM
Equipment Maintenance
Maintenance must be performed with clear roles. We must decide who will maintain what parts of equipment
(Jishu Hozen)
Overview of TPM
What equipment? Evaluate the criticality of the equipment based on P,Q,C,D,S and M criteria and classify the equipment
What parts? Practical decision making through step activity of Jishu Hozen and Keikaku Hozen . Logical decision making,through the application of FMEA, FTA, PM analysis, RCM (Reliability Centered Maintenance) etc BM (Breakdown maintenance) What maintenance method? Select from the following maintenance methods for each part. Selection depends on the criticality of the equipment. TBM (Periodic maintenance) Inspection and Repair (Overhaul) CBM (Predictive maintenance)
5W1 H method should be used to draft the standard maintenance procedure Carryout maintenance systematically Maintenance tasks must be performed systematically based on the maintenance calendar and standard maintenance procedure.
Overview of TPM
3 Insufficient Strength
Stress and strength
Failure : c Time
Overview of TPM
Uncontrolled stress
Neglected deterioration
Insufficient strength
Overview of TPM
Five Factors
1
Five Countermeasures
1
Inadequate compliance with basic requirements Non-compliance with usage requirements Neglected deterioration Inherent design weaknesses Lack of skill
Adequate compliance with basic requirements Compliance with usage requirements Restoration of deteriorated equipment condition Rectification of design weaknesses Improvement of operation and maintenance skills
3 3
Overview of TPM
4. MP activities
JIPM, 1994
Input Reduction
(Source : processing and Assembling New TPM Implementation Program, Page 244)
Overview of TPM
Failure reduction activity Rank equipment criticality Select the equipment parts to be maintained Select maintenance method Draft standard equipment maintenance procedure Practice preventive maintenance (PM) based on maintenance calendar
Overview of TPM
Overview of TPM
Step 1
Step 2
Step 3
Step 4
Step 5
Support for initial cleaning Red tag removal and support to deal with areas with difficult access Production skill Education Preliminary Education for total inspection skills (Preparation) Preliminary education for total inspection skills (implementation) Why-Why analysis (for the production department) Record and Analyse each breakdown Thorough restoration and improvement activities against deteriorated parts Activities to prevent recurrence of breakdowns Preliminary education for total inspection skills (implementation)
Breakdown maintenance is widespread Breakdown repair is the primary job Many think zero breakdowns is impossible
Deploy all the three activities mentioned left-hand side to all the equipment
Rectify equipment weakness (Implement corrective maintenance) Review maintenance system Rank equipment based on criticality and select maintenance method
Draft the standard inspection and maintenance standard procedure
3. Establish maintenance planning Delay in building system management Lack of proper planning Establish Keikaku Hozen Breakdown maintenance management Classify equipment based on criticality and draft the maintenance standard 4. Maintenance information management system development Information management useful for preventive maintenance Computer management 5. Spare parts control Control to support preventive maintenance Reduce the cost of retrieving, replenishment and administration 6. Predictive maintenance system development Research the optimal maintenance time Strive to minimize maintenance cost 7. Lubrication management Eliminate failures caused by defective lubricant or working oil Reduce management cost 8. Maintenance skill education Improve failure prediction capabilities Establish maintenance system run by selected elite Only data collection is done Information is not used
Practice maintenance based on maintenance calendar Record Analyse each breakdown Prepare maintenance information computerization Implement maintenance information computerization
Lack of control or no control at all Response is given only when emergency Incapable of implementing predictive maintenance. Only simplified diagnosis is implemented Throwing responsibilities to the shop floor Only the total usage is controlled Education is focused mainly on repair skill Insufficient knowledge of diagnosis Low awareness
Carryout seiri-seiton for spare parts Determine what items and what quantity should be stoked Draft the spare parts control standard Study the needs of predictive maintenance Learn equipment diagnostic techniques
Model activity
Select the equipment and parts to be diagnosed Accumulate data based on simplified diagnosis
Investigate and integrate various types of oils Promote visual control system. Indicate oil level, oil type etc.
Review oil standard
Study the technical aspects of oils and select the optimal oils
Draft the lubricant control standard
Enlighten and educate through practice (learn from breakdowns) Participate in seminar organised by JIPM Plan and implement skill evaluation and education for each individual
Overview of TPM
PILLAR
Overview of TPM
Confirmation of working conditions Daily inspection Periodical inspection Activities to prevent equipment degradation
justm ent
of ill k s or or Po erat op
ss Yield lo
Keep cleaning Inspection Additional tightening Activities to restore the machine conditions
Preventive Maintenance
TPM
U.S style of PM
Maintenance Departments sole responsibility
JH -61
Overview of TPM
Overview of TPM
MAINTENANCE
Production do not know how to operate We get lot of r5epairs sew we dont have ample to do a real corrective action and are forced to do only temporary job We prepare the standards but they do not do the checks
JH -63
Overview of TPM
EQUIPMENT DETERIORATION
Natural Deterioration Extend Life Time Corrective Maintenance Prevent errors by improving operability Improve Maintainability & Repair Quality Improve safety & Reliability Accelerated Deterioration Eliminate Causes Establish Basic Condition Cleaning : Eliminate all dust & Dirt Lubricating : Keep lubricants clean and replenished Tightening : Keep nuts & bolts secure
JH -64
Overview of TPM
Overview of TPM
Proper Operation Normal Operation Set-up and adjustment Cleaning, Address Latent Defects
Lubrication
Minor Check Time based Maintenance Productive Maintenance Time based Inspection Time based Inspection Time based Check Tend Check
Unscheduled Check
Corrective Maintenance
Others Maintenance Prevention Breakdown Maintenance MP Activities Planned Breakdown Maintenance Emergency Maintenance
Earlier discovery of interior situation and positive and rapid report/remedy Sporadic Repair
JH -66
Overview of TPM
Formulation of clean-up and Formulate behavioral standards so that it is possible to steadily sustain clean-up, lubrication standards lubrication and machine parts adjustment in a short period (Necessary to indicate a time frame-work that can be used daily or periodically).
Overall inspection
Training in check-up skills through check-up manuals; exposure and restoration of minor equipment defects through overall check-ups Formulation and implementation of autonomous check-up sheets Standardize various types of on-the job management items and devise complete systematization of up-keep management. Standards for clean-up, check-ups and lubrication Standards for physical distribution in the workplace Standardization of data records Standardization of die management, jigs and tools
5 6
All-out management
autonomous Development of corporate policies and goals, and making improvement activities routine : Steadily record MTBF analysis, analyze these, and carry out equipment improvements
JH -67
Overview of TPM
Overview of TPM
Overview of TPM
Areas / Parts
Overview of TPM
7 types of abnormalities
1. 2. 3. 4. 5. 6. 7. Minor Flaws Unfulfilled Basic Conditions Inaccessible places Contamination sources Quality Defect Sources Unnecessary and non-urgent items Unsafe places
JH -71
Overview of TPM
1.MINOR FLAWS
Contamination Damage Play Slackness Abnormal Phenomenon Adhesion Dust, Dirt, powder, oil, grease, rust, paint Cracking, crushing, deformation, chipping, bending, Shaking, falling out, tilting, eccentricity, wear, distortion, corrosion, Belts, Chains Unusual noise, overheating, Vibration, strange smells, discoloration, incorrect pressure or current Blocking, hardening, accumulation of debris, peeling, malfunction
JH -72
Overview of TPM
JH -73
Overview of TPM
3. INACCESSABLE PLACES
Cleaning Checking Machine construction, Covers, Layout, footholds, Space Construction, Covers, Layout, footholds, Instrument position and Orientation, Operating Range display
Position of lubricant inlet, construction, height, footholds, lubricant outlets, space Covers, Construction, Layout size, Space Machine layout, Position of valves, Switches and leavers, Footholds Position of pressure gauges, thermometers, flow meters, moisture gauges, vacuum gauges, etc.
JH -74
Overview of TPM
4. CONTAMINATION SOURCES
Product Raw materials Lubricants Gases Liquids Scrap Others Leaks, Spills, Spurts, Scattering, Overflow Leaks, Spills, Spurts, Scattering, Overflow Leaking, Spills, Seeping oils, Hydraulic fluids, Fuel oils, etc. Leaking compressed air, gases, steam, vapors, exhaust fumes, etc. Leaking water, Hot, Cold, half finished products, Waste water, Leaking supply lines etc. Flashes, cuttings, packaging conforming products. materials, and non
Contaminants by people & Forklifts, Infiltration through cracked walls, broken windows etc.
JH -75
Overview of TPM
JH -76
Overview of TPM
JH -77
Overview of TPM
7. UNSAFE PLACES
Floors Steps Lights Rotating machinery Lifting Devices Others Unevenness, cracked, holes, projections, peeling, wear of steel chucker plates, slipping. Too steep, irregular, slipping, missing handrails, etc. Dim, out of position, dirty or broken covers, no explosion proofing, etc. Displaced, fallen off or broken covers, not safe for emergency, missing emergency stop devices Wires, hooks, brakes and other parts of cranes and hoists etc. Special substances, solvents, toxic gases, insulating materials, danger signs, protective clothing etc.
JH -78
Overview of TPM
Equipment Name Control No.. Date of detection. Detected by.. Description of Minor defects . .. .
Equipment Name Control No.. Date of detection. Detected by.. Description of Minor defects . .. .
JH -79
Overview of TPM
JH -80
Overview of TPM
STEP 2
Countermeasures against sources of contamination Make approach easy for CLRI Make easy to do CLRI Shorten cleaning , lubricating time Adopt concepts of localized guards Ranking the priority places for daily cleaning
JH -81
Overview of TPM
STEP 3
Standards for cleaning, lubricating and tightening Standards are made by operators themselves with guidance by pm
Standards are made by using 5w 1h Standards should be easily understood by every one Introduce extensive visual controls
JH -82
Overview of TPM
MONTH : JANUARY
12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
1 1a 1b 1c 1d 2 2a 2b 2c 2d
HYDRAULIC TANK FRONT Outer body Pipe Joints Oil level indicator Oil pressure Gauge LUBRICATION TANK Tank outer body Level indicator El. Jn. Wiring Lub Pipe joints 3M
No Leak No dirt & dust btwn. Max & Min. No dirt & dust No Leak btwn. Max & Min. in Green Zone
LEGENDS - (
) - OK ,
) - NOT OK ,
) - PLANNED.
JH -83
Overview of TPM
Illustration
Classification
No.
Place or section
Standards
Method
operation stoppage
Tail stock
Inspection
Tailstock
Visual
1 , 1
3mm Allenkey
OP
b b b b
Cleaning Inspection
2 3
Free from mist & dust With in the indicated value range
30 2
W W
OP OP
Inspection
Loader Pistion
No Damage
1200 1 M
OP
Overview of TPM
JH -85
Overview of TPM
VISUAL CONTROLS
Activity
Symbol
Tools
CLEAN
, 6 12&
JH -86
LUB
INSPECTION
Overview of TPM
4 Master how to repair the equipment Learn how to operate the equipment with the required 3 accuracy and how to evaluate the product quality Study the mechanism and 2 functions of equipment and machines Familiarize with the concept of equipment maintenance and improvement and with how to put the idea into practical realization
6 Orderliness and tidiness 5 Autonomous check-up 4 General inspection 3 Formulation of clean-up and lubrication standards 2 Measures against sources of outbreaks
1 1 Initial clean-up
JH -87