Kick out TPM implementation proposal for 2008

What is TPM?
 TPM is not only a tool or a methodology. It is a coherent and
structured group of methodologies capable of spanning the entire
business if required.

 TPM is an innovative philosophy, which works with new and

existent processes, in big and small businesses.

 TPM is a support to the autonomous way of working, integrating

tools in a step-by-step system.
 Brief of Total Productive Maintenance
Most of the problems of the various companies usually are ³Maintenance´.

Is the mean of maintenance µnecessary evil¶ or µextra expenses¶?

Is the mean of maintenance µmachine reliability and availability¶?
TPM is a very powerful tools that will answer this questions and the
answer will not be in written but in results.
In this case what should be the view of implement TPM?
The view of implement TPM should be:
1. Elimination of machine losses;
2. Increase of productivity and product quality;
3. Reduction of cost, accident and environmental pollutions; and
4. Pleasant working environment (witch is very important).
 TMP Definition

The definition of Total productive maintenance changes from various

authors but the content is the some. So taking definition from (

  
TPM is ºMaintenance system that merges total employee involvement,
quality improvement, and state of the art of maintenance technology to improve
the equipment capacity utilization of the plant and the quality of the productf
 Important notes
4


   

1. In some companies that have filed to obtain the understanding of top

management involvement, TPM has remained a middle involvement of
various stage of activities. In such companies, the total employment
involvement required by TPM has not occurred and the activities have
ultimately ground to a halt.

2. Unless a clear understanding is achieved in the all company, them

people can may see the increase of productivity and capacity, and use
TPM as lever to drive the organisation.

3. Employment involvement can decrease until the TPM initiative grinds

to a halt if there is no involvement of entire management people .
 Why we need to start TPM in Machava?
1. We have committed to implement TPM (autonomous
maintenance) in our BBP for 2008;
2. Maintenance is very dynamic process that is evaluating
constantly. If we don¶t use TPM now, on the time we start using
there will be another methodology of maintenance and Machava
will never be up to date in terms of maintenance methodology.
3. We need improve and sustain our OEE to 95%;
4. Others plants in the group (NBL and CBC) have started and they
are showing good results;
5. Autonomous maintenance will help to improve accountability of
the machines and assessment of machine condition;
6. It is easy and practical way of improve technical labor skills;
7. This is a good way of have all levels of personnel to fell
involvement on the business.
 What is the results expected from this program?
1. Increase of productivity in terms of volume by having low
downtime;
2. Increase quality in terms of low compliance of product as there
will be more accountability from the line operators;
3. Increase maintenance service quality as service assessment
start from the operators and problems will be addressed from
the root cause;
4. Reduce machine and personnel incident and accident by having
all personnel (operators and technicians) performing basic
operation and maintenance safety procedure;
5. Increase employee morale by giving training; creating ownership
culture; and creating participation and motivation on the
program;
6. More people involved on preventive maintenance activities
during maintenance days reducing time and overtime during the
weekends;
7. Provided technical capability built at very low cost.
 Implementation proposal
1. Draw clearly rolls and responsibility for machine operators and line
technicians;
2. Set operators machine accountability and technician responsibility;
3. Organize a meeting explaining all production and maintenance team
about autonomous maintenance and rolls and responsibility for every
one;
4. Walk about picture must be taken for all the machines to show the
current status;
5. Set up a day and people for machine general cleaning. This includes
involvement of all managers;
6. All defects found on cleaning day must be reported, compiled and work
order opened. Clear corrective maintenance plan must be done in order
to eliminate all of this defects. Follow up process must be clearly
defined;
7. Start on the job training of machine lubrication and tightness, mainly for
packer and Un-packer, Washer, and Filler for the respective operators. A
cleaning must be monitored daily by specified committee until the
cleaning culture is in place;
8. All maintenance work order for the machine must include line technician
and machine operators. Machine maintenance must not be done with
operators absence.
 Witch tools needs to be in place?

1. There needs to be provided one grease gun per each referred machines;
2. One oil lubricator pump for each referred machine;
3. One basic wall tool box for each area of the line, dray and wet area
respectively;
4. One maintenance request book localized near the wall tool box.
Operators needs to be teach and coached on how to fill maintenance
request book;
5. Clear strategy of spare part availability on the store in order to not de-
motivate people during implementation of the program. Procurement
involvement is most required;
 Witch systems and routines needs to be in place?

1. Job assessment for each and single maintenance request needs do be

done by respective supervisor and maintenance planner;
2. Job card needs to be issued in daily basis for the operators and
technicians in order to ensure that all the jobs are done as per plan and
easily monitor backlog on the system;
3. The operators needs to clearly understand the flow process of corrective
maintenance request;
4. Each maintenance activities needs to have indication of time, tools,
spare part, cost, health and safety procedure and relevant work permit;
5. Machine audit plan for 2008 needs to be strictly followed by maintenance
personnel and respective CAP followed;
6. Post maintenance evaluation meeting needs to happen between
maintenance, production and procurement so everybody can understand
the importance of they roll on the business and possible consequence of
not performing the agreed planning activities.
 Rolls and responsibility
Goal Objective Task description Responsibility

   

 





 




      

 


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Are we ready to roll this program
proposal?