TPM IMPLEMENTATION

PRESENTED BY PAT WHITE

PROCESS AUTOMATION & MAINTENANCE
MOLEX IRELAND LTD.

MEETA ANNUAL CONFERENCE

ENGINEERS IRELAND, CLYDE ROAD, DUBLIN

TPM IMPLEMENTATION PLAN

MOLEX IRELAND SHANNON

In Shannon more than 40

years; opened in 1971
Connector manufacture &
PCBA
Rapid Growth in the late 90s
designing and building
connectors for the Mobile
Phone Industry
In 2008 Molex Ireland moved
to Value Streams as part of the
Lean manufacturing initiative
started in 2000-2001
Currently employing 450
employees

TPM IMPLEMENTATION PLAN

TYPICAL MOLEX PRODUCTS

TPM IMPLEMENTATION PLAN

MOLEX SHANNON - STAMPING

Stamping Copper Alloys for

Connector Conductivity
Stamping Stainless Steel for
Mechanical Functionality

Contact Fabrication using

Resistance & Laser Welding

TPM IMPLEMENTATION PLAN

MOLEX SHANNON - PLATING

Gold Plating for

Electronic Applications
Other Plating
requirements are:
Corrosion Resistance
Contact Resistance

TPM IMPLEMENTATION PLAN

MOLEX SHANNON - MOULDING

Moulded Plastic
components
provide Insulation
Resistance and
other Functionality
Multiple:
Colours
Polymers
Process types

TPM IMPLEMENTATION PLAN

MOLEX SHANNON - ASSEMBLY

Assembly of Metal &

Plastic Components
to make Connectors
Fully Automated
Assembly, Packaging
and Inspection

IMPLEMENTATION OF TPM
BUSINESS CASE
Business Metrics performance

Footnotes

Gross Margin \ COS Metrics

Plant OEE
Utilisation of Assets; Equipment, People & Material
Quality Notifications
Delivery Performance to CRD
Plant Position on Global MX Scorecard
Experience with Lean Manufacturing Black Belt &
Green Belt Capability

TPM IMPLEMENTATION
BELOW WERE THE TYPICAL BEHAVIOURS THAT DESCRIBED OUR APPROACH!
Break the Cycle of Reactive to Prevention Activities in Operations

Equipment Losses Often Occur because the Root Cause of a

Problem is not Eliminated
Production Pressure and Other Constraints prevent a Thorough
Investigation of Problems
Pit-Stop & Quick Fixes are made which often Result in
Performance & Quality Losses During Operation
In Many Cases Defects That Dont Cause a Breakdown are Ignored
and become Part of the Operating Cycle of The Equipment
Eventually these Defects Recur & Magnify, the same Fixes are
Applied (Under the same Pressure) and the Cycle Continues
With TPM the trick is to prevent reoccurrence with the 100 yr fix

IMPLEMENTATION OF TPM
TPM JOURNEY WE LOOKED OUTSIDE
Benchmarking & Analysis

Attend Lean Seminar @ SNN Aerospace

Visit Lake Region to witness TPM at work
Engage TPM Consultant (Peter Willmott)
BLT TPM Buy-In Workshop (Maintenance Survey)
Select Processes for TPM Projects (MCs with high
demand & unreliable performance)
Select Projects, Team Leaders & Team Members

TPM IMPLEMENTATION
TPM 9 STEP PROCESS

WHAT MAKES IT WORK : ONE OF OUR TPM TEAMS

A functioning cross functional Team including all stakeholders unlocks the
hidden potential and knowledge that already exists!

TPM IMPLEMENTATION
TPM JOURNEY CONTINUED
Launch Pilot Projects in Moulding Area

Project 1: 24\7 Machine with OEE approx. 47%

Project 2: Overmoulding Process consuming significant
Tooling Spares & Toolmaker Hours due to Mould Crashes,
OEE was not the primary metric
Both Projects have been very successful
Project 1 achieves OEE > 80% giving up to 50% capacity benefit
Project 2 has been redesigned & Tooling breakages are Minimal
Reliability has been greatly enhanced on both assets so that we
can forecast delivery of the production plan with confidence on
time in full

TPM IMPLEMENTATION
TPM JOURNEY BEING SUSTAINED
Pilot Project Success provided platform to kick-off new Projects and
add Resources

TPM Projects kicked-off in the other

Manufacturing areas such as:
Automated Component Assembly Machines
Automated Metal stamping Machines
Total # is 17,Two Pilots have passed L4
Project Status
L1

L2

L3

L4

TPM Total Productive Manufacturing

Out of Control
High scrap costs
More likely to cause
QNS.
Capacity constraints
Poor reliability
More changeovers.

In Control
Reduced Scrap costs
More process capability
Unlock capacity
Improved c/o strategy.
Increased profitability

15

TPM IMPLEMENTATION
TPM SUCCESS

Benefits from initial 13 Projects

Safer work environment

Hassle free shift creates belief
83% Increase in Productive
Capacity - giving us choices
Production Planning have
more confidence hence less
C\Os and longer Runs
Clear QN & COS Gains
Roll out Standard Work & Best
Practice to Sister MCs &
Processes

TPM IMPLEMENTATION
TYPICAL TPM PROJECT DISPLAYS

WHAT WE FOUND DIFFICULT AND WHAT IS WORKING FOR US

FLOAC - still some insecurity around taking the Time for

Cleaning, Checking & Inspection!
Initially we struggled with the Nine Step Process Two
Stepping
Formalising Standard work and carrying out Technical
Training
Self-directed Teams require Management to trust to
delegate
Ideally the TPM driver needs to have the ability to
connect with everyone from Operators to Managers
TPM & Team Leader Training is essential
Weekly shop-floor Project Reviews create a strong link
between Management and Manufacturing

TPM IMPLEMENTATION
OUR EXPERIENCE:

Culture Change
TPM is a key CI Enabler
Good results and success generate enthusiasm and pride
The Nine Step Process is very practical & engages people at
all levels.
TPM Training sessions and Assessments have been very
effective in getting employees engaged in the Process.
TPM Terminology gets embedded : OEE, Spot the Rot, 100
Year Fix, Best Practice, FLOAC, Condition Monitoring,
Improvement Priorities.
TPM highlights gaps in Training and other support functions
Good communication at all levels enables less risk in
decision making i.e. Design changes, Investment, strategy