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LEAD TIME
REDUCTION
PEOPLE
SUPPORTIVE
PRACTICE
20
KEYS
LEVELING/
SMALL LOT
EMPLOYEE
INVOLVEMENT/
WHITE SHIRT
PROCESS
CAPABILITY
SIX SIGMA
Pull
System
SUPPLIER
DEVELOPMENT
QUICK
SET-UP
CONTAINER
-IZATION/
TRANSPORTATION
ERROR
PROOFING
PLANT,
MACHINE,
OFFICE
LAYOUT
WPO
&
VISUAL
MANAGEMENT
TOTAL
PRODUCTIVE
MAINTENANCE
TPM STRATEGIES
Loss
Elimination
Operator
Autonomous
Maintenance
Planned
Maintenance
System
Six
Supporting
Strategies
To TPM
Initial
Control
System
Education
And
Training
Zero
Defects
L in u m fla v u m l.
6
10
11
12
TPM . . . . . What It Is
A support process for AMPS.
Upgrading and improving equipment.
A people skill building and training
process.
Part of daily activities.
13
Competition
Current Condition
JIT
. . . . To Support AMPS
14
To:
Japan - Nippon Denso - Productive Maintenance
15
Total
Productive
Perfect
Maintenance
Management, System
Control
16
Definition:
A set of activities for
restoring equipment to its
optimal condition and
changing the work
environment to maintain
those conditions through
daily maintenance activities.
17
Objective:
To restructure the
corporate culture
through behavioral
changes and equipment
improvements.
TE
AR
DOW
N
THE
LL
WA
18
Intent:
To upgrade the capabilities
of all company members
through education, training,
and participation.
TPM
19
Purpose:
To identify productivity
losses and involve all
members of the company
in loss elimination
programs.
L O S S
20
Job Security
Improved Quality
Increased Productivity
Improved Skills
21
LEAD TIME
REDUCTION
PEOPLE
SUPPORTIVE
PRACTICE
20
KEYS
LEVELING/
SMALL LOT
EMPLOYEE
INVOLVEMENT/
WHITE SHIRT
PROCESS
CAPABILITY
SIX SIGMA
Pull
System
SUPPLIER
DEVELOPMENT
QUICK
SET-UP
CONTAINER
-IZATION/
TRANSPORTATION
ERROR
PROOFING
PLANT,
MACHINE,
OFFICE
LAYOUT
WPO
&
VISUAL
MANAGEMENT
TOTAL
PRODUCTIVE
MAINTENANCE
22
23
Unit
Maintenance/Tool Personnel
Unit
Management
Plant
Management
24
25
Photo Of
Operators In Initial
Clean-Up
26
Photo From
Presidents CleanUp
27
28
29
30
31
32
33
34
35
36
37
Quality:
Reduction
Cost:
Production
accidents.
5 -- 10 suggestions per employee.
Education:
Skill
upgrading of employees.
39
Before
Labor As A % Of Sales
28.9%
Scrap As A % Of COS
5%
Finished Goods Inventory5 Days
After
AMPS
After
TPM
21.2%
1.5%
1.2 Days
18 %
0.7%
0.5 Days
Cost Of Quality
Parts Per Million
15%
2500
5.6%
37
4.0%
7
Delivery
98%
100 %
100 %
40
55.00%
40%
30%
20%
15.00%
10%
0%
8.00%
Corrective
Preventive
Predictive
41
Lack Of Lubricant
24.0%
42
Other Equip.
Failures
51%
Lack Of
Lubricant
24%
Source: JIPM
43
TPM Measurements :
Downtime
# of Equipment Failures
Planned
Minor Stoppages
Unplanned
Maintenance Costs
Accidents
Changeover Time
Clean-up Time
44
MEASUREMENTS
In-Company Defect Cost Rate
Delivery Rate
1200 PPM
Better
800
600
8
Point
s
95
1
3
90
Better
1000
Percent, %
400
85
200
'90/9 '91/3 '91/9 '92/3 '92/9 '93/3 '93/9
80
'90/9 '91/3 '91/9 '92/3 '92/9 '93/3 '93/9
45
MEASUREMENTS
Improvement Suggestions
Accidents
Better
4
3
80
60
40
20
0
1990
1991
1992
Better
100 Suggestions/Year
5 Accidents/Year
1993
32
Times
1990
1991
1992
1993
46
47
48
49
VIDEO
INTRODUCTION
TO TPM
50
BREAK ?
BREAK !!!
BREAK!!!!!!!!!!!!!
51
EDUCATION
52
53
Levels Of Skills
Level 0 Do Not Know
Lack Of Knowledge
Lack Of Training
Lack Of Training
Learned By Doing
54
55
Category
ACTUAL
RESULTS
Date Of
Preparation
Basic
Knowledg
e
Kaizen
Cases
Trouble
Cases
Team
Leader
SuperUnit Prepared
visor Manager
By:
Date Executed
Teacher
Student
57
58
No.
Theme
Category
Visual Control
Basic
Knowledg
e
Kaizen
Cases
Date Of
Preparation
Trouble
Cases
Team
Leader
KF
5-Feb. 2002
SuperUnit Prepared
visor Manager
By:
DR
MA
CR
-----
Current level
Site Gage for hydraulic fluid: Oil must stay within the Full
And Low level lines.
ACTUAL
RESULTS
59
60
No.
Theme
Category
Error Proofing
Basic
Knowledg
e
Kaizen
Cases
Date Of
Preparation
Trouble
Cases
Team
Leader
KF
5-Mar. 2002
SuperUnit Prepared
visor Manager
By:
DR
MA
CR
Clamp
Flange
Locator
Switch
ACTUAL
RESULTS
Clamp
61
62
No.
Theme
Category
Tool Brealage
Basic
Knowledg
e
Kaizen
Cases
Date Of
Preparation
Trouble
Cases
Team
Leader
KF
5-Jun. 2002
SuperUnit Prepared
visor Manager
By:
DR
MA
Before Condition:
Frequent arbor breakage
CR
Arbor
--
--
Key
Break
Improved Condition:
Relocated key
ACTUAL
RESULTS
Key
Arbor
63
Step #4
Upon completion of the 3rd Step, the team
will participate in the TPM Step #4 classes.
This will lead the team into the individual
support classes for the various machine
elements. The team will study the elements
on the following slide.
65
Equipment
OIL
Safety
Lubrication
Hydraulics
Pneumatics
Drive
Systems
Electrical
Machine
Systems
Systems
66
VIDEO
PARADIGMS
67
LOSS ELIMINATION
68
Aware
Chronic
Loss
Almost
CounterA measures
Taken
No satisfactory results
Giving
No sign of improvementUp
Unable To
B Take Necessary Action
Unaware
Cause
Cause
Cause
Cause
Cause
Cause
Understanding
The Cause
72
73
Design
Manufacturing
Installation
Operation
Maintenance
74
What Are
Slight Defects?
75
Photo Of
Shavings On Bender
76
2 Types Of
Equipment Deterioration
Natural Deterioration: Physical wear that occurs
even though the
equipment is used and
maintained properly.
Forced Deterioration: Natural deterioration that
is increased from
negligence on our part,
such as lack of oiling,
checking, repairing, etc.
78
Photo Of
A Bar Leaning
On A Machine
79
Latent Defects
Are . . . .
Seeds
80
Psychological:
Not Visible
Need To Disassemble
Hidden Behind
Covered By Dust, Stains, Etc.
Left Ignored Because Of Lack of
Interest Or Skill
Operator & Maintenance
Indifference
Not Familiar With The Defect
Error In Judgement Of The
Defect
81
2 Types Of Failures
Function Stoppage:
Failure
83
FAILURE
LATENT DEFECTS
Dust, soiling, adhesion of raw materials.
Abrasion, backlash, looseness, leaks
Corrosion, deformation, flaws, cracks
Temperature, vibration, sound, and other errors
84
How To Eliminate
Failures To Zero
1. Establish Basic Conditions
2. Maintain Operating Conditions
3. Restore Equipment From A Deteriorated State
4. Improve Weak Points Of Design
5. Upgrade The Skill Level
85
Loss Elimination
2.
Operator Autonomous
Maintenance
3.
Restore Equipment
From A Deteriorated
State
Planned Maintenance
4.
5.
86
16 Major Losses
Which Obstruct Production Efficiency
87
1. Management Loss
2. Operating Motion Loss
3. Line Organization Loss
4. Logistics Loss
5. Measurement &
Adjustment Loss
88
1. Energy Loss
2. Die, Tool, & Fixture Loss
3. Material Loss
89
Equipment warm-up
and stabilization
91
Photo Of
Operator Pushing A Reset
92
8. Shutdown Loss:
Planned stoppage of
equipment
93
How Do We Plan
To Realize
Our Losses
TPM
94
TPM Measurements:
Downtime
-- Planned
-- Unplanned
# Of Equipment Failures
Minor Stoppages
Changeover Time
Maintenance Costs
Accidents
Clean-up Time
Defect Rate
95
Measurement Details
Downtime:
-- Planned
Scheduled
production stoppage
-- Unplanned
Production stoppage
due to equipment
failure
96
Measurement Details
Unplanned Downtime:
--This category of downtime is made
up of the 8 Major Losses Which
Obstruct Equipment Efficiency.
97
Measurement Details
Planned Downtime:
--This category is made up of
scheduled production stoppages.
98
Measurement Details
Changeover Time:
-- Time period from last good piece
produced to the first good piece
produced on the new part number
safely.
99
Measurement Details
Equipment Check Time:
-- The amount of time required to
perform daily checks on the
equipment. This time is from when
the checks begin until all checks are
complete on the cell
100
Measurement Details
Clean-up Time:
-- The amount of time required to
perform daily clean-up of the
equipment and surrounding area
101
Measurement Details
# Of Equipment Failures:
-- Total number of equipment failures
on a cell during the shift
102
Measurement Details
Minor Stoppages:
-- Number of equipment minor
stoppages during the shift
103
Measurement Details
Maintenance Costs:
-- Associated costs for maintaining the
equipment on a line. These costs
include all replacement parts cost and
the labor required to replace the parts.
Also included in these costs are the
cleaning supplies to maintain the
equipment
104
Measurement Details
Accidents:
--
Number of accidents on a
cell . . . . . . lost time and not
lost time
105
Measurement Details
Defect Rate:
-- Defects generated by process
106
TPM TRAINING
Loss
Elimination
Operator
Autonomous
Maintenance
Planned
Maintenance
System
Six
Supporting
Strategies
To TPM
Initial
Control
System
Education
And
Training
Zero
Defects
107
108
What Is
Operator Autonomous Maintenance?
Activities where each operator
performs timely inspection,
lubrication, consumable parts
replacement, repair,
troubleshooting, accuracy checks,
etc. . . . . on their own equipment.
109
110
TPM Roles Of
Establish
Basic
Conditions
Keep
Operation
Conditions
Prevent
Machine
From
Deteriorating
Operators
Improve
Weak
Points In
Design
Improve
Skill
Maintenance
Management
111
Prevent Deterioration
Measure Deterioration
Repair Deterioration
112
Photo Of
Repairing Problem
113
Photo Of
Repairing Problem
114
Measure Deterioration
Repair Deterioration
115
116
PRELIMINARY STEP 0
Before starting the step method, the
following should be done.
117
118
119
120
VIDEO
LOCK OUT
TAG OUT
121
STEP 1:
Initial Clean-Up
Cleaning Is Inspection:
122
123
124
125
126
127
Photo Of Cleaning
128
129
Photo Of Cleaning
130
STEP 1:
Cleaning is Inspection:
Using TPM Problem Tags:
Tags to be filled out by all operators
Attach tags to problem location
Each problem requires its own tag
BLUE TAG -- Operator responsible to
repair
RED TAG -- Maintenance group
responsible for
repairs
131
TPM
TPM
Autonomous Maintenance
Step. No.
12 3 4 5
Problem Found Here
Equipment:
A
: sset No.:
Date Found:
Found By:
Description of Problem:
Autonomous Maintenance
Step. No.
12 3 4 5
Problem Found Here
Equipment:
A
: sset No.:
Date Found:
Found By:
Description of Problem:
Page 1
Page 2
Date
Repaired:
Repair
Made By:
Description of Repair:
Page 3
132
133
134
135
136
Tag History
Upon completion of the repair, log or file tags for
future reference. Keep the information at the cell.
Red tag history highlights:
Recurring problems
Repair history
Maintenance response
Blue tag history highlights:
Operator repairs and minor stoppages
Recurring problems that need to be red tagged
137
Photo Of Problem
138
Photo Of Problem
139
LUNCH !!!
FOOD!!!!!!
140
Floor Exercise 1
Initial Clean-up
1. Participants will go to the designated cell
2. Facilitators will assign participants to a
specific piece of equipment or area
3. Using the proper cleaning material and
TPM tags the participants will clean the
equipment and tag all problems.
Continued on next slide
141
142
Step 2
143
1.
2.
3.
4.
144
145
146
Source of Contamination
After
147
148
149
Try
2
1
Improvement
Fabricate Temporary Device
Using Galvanized Steel Or
Other Material
Produce Final Device
Suggest As
Standardization And
Future Design Information
150
151
HTA SOC
Description
Of
Problem
Item
Cleaning,
Lubrication,
Inspection
Completion
Countermeasure
Who
Who
Found Responsible
Target Actual
152
Floor Exercise 2
Participants will be given the Hard to
Access & Source of Contamination
documents to fill out at the cell.
Allow 30 minutes to complete this form.
Return to the training room for the Report
Out.
153
Step 3
154
155
156
157
Line
Machine
Effective Period
Team Leader
Supervisor
Unit Manager
Year
Month
Zone
No.
Description
I.C.L.
What To Do &
Items Used
How
Often
Who
Target
Time
158
Sample Of
Temporary Standard Check Sheet
159
Sample Of
Temporary Standard Check Sheet
160
Floor Exercise 3
Participants will return to the floor
and fill in a Temporary Standard
Check Sheet.
Return to the training room in 30
minutes for the Report Out.
161
Implementation
&
Review
162
TPM Requirement
A
M
P
S
C
H
A
M
P
I
O
N
S
AMPS Review
163
164
Program Outline
165
166
Transmission Of Education
Standardization
Activities Board:
Timing Chart
# Of Equipment Failures
# Of Minor Stoppages
Changeover Time
"Before" & "After" Pictures
Clean-up Time
Maintenance Costs
167
Quick Repair
TPM Meetings
Step System
Step Review
Promote Success Stories
168
Stage 1
Step 2: Countermeasures For Hard-ToUpgrading The Basic
Access & Source Of
Conditions Of The Equipment
Contamination
Step 3: Prepare Temporary Standards
Step 4: General Inspection
Step 5: Autonomous Inspection
Step 6: Standardization
Step 7: All-Out Autonomous
Management
Stage 2
Steps To Measure &
Prevent Deterioration
Stage 3
Steps To Expand OAM &
Master The Maintenance Skills
169
Stage 1
Upgrading The Basic
Conditions Of The
Equipment
Stage 2
Steps To Measure &
Prevent Deterioration
Stage 3
Steps To Expand OAM &
Master The Maintenance
Skills
170
Mazda Express
TEAM NAME____________
MARCH
APRIL
MAY
JUNE
6 13 20 27
3 10 17 24
1 8 15 22 29
5 12 19 26
3
172
173
Aut. Mgt.
Standardization
Autonomous Inspection
General Inspection
Prepare Temporary Standards
Countermeasures for Hard-To-Access & Source Of
Contamination
Initial Clean-up
7
6
5
4
3
2
1
174
TPM STRATEGIES
Loss
Elimination
Operator
Autonomous
Maintenance
Planned
Maintenance
System
Six
Supporting
Strategies
To TPM
Initial
Control
System
Education
And
Training
Zero
Defects
175