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A STRATEGY FORPERFORMANCE EXCELLENCE1Performance Excellence SeriesTraining Module ElementsExecutive OverviewParticipant manualTools WorkbookKnowledge BreakthroughLecture notesLecture notes2Table of ContentsExecutive OverviewSession 1.0Introduction.3Session 2.0Role in Lean Manufacturing.8Session 3.0Role of the Operator in TPM.18Session 4.0Autonomous Maintenance Implementation22Session 5.0Equipment Performance:Measurement&Management.563Total Productive MaintenanceDo these problems sound familiar?nEquipment is always breaking downnOperating machines at rated speeds creates defectsnSetups and adjustments take too longnMinor machine stoppages are eroding productivity4Total Productive MaintenanceA series of methods to ensure that process machines are always able to perform their functions so that production is never interrupted.5Total Productive MaintenanceWhat it is:1.Optimizes equipment efficiency2.Implements a company wide Preventive Maintenance system3.Involves production equipment designers,operators,and maintenance department personnel4.Involvement from Management down to floor workers5.Implemented through small,self directed team activities6Total Productive MaintenanceTypical success results after implementation of TPM:Breakdowns:1/30 to 1/100 of prior levelMachine defects:1/30 to 1/40 of prior levelProductivity:30-100 percent increasesource:K.Shirose,TPM For Workshop Leaders,p.107Performance Excellence:Expanding the Strategy through TPM IntroductionRole in Lean ManufacturingRole of the Operator in TPMAutonomous Maintenance ImplementationEquipment Performance:Measurement and Management8The Nine types of wasteOverproductionDelays(waiting time)TransportationProcessInventoriesMotionsDefective productsUntapped resourcesMisused resources 9 WastesTPM targets reduction of these equipment oriented wastes9Yesterday:Problem=machine breakdown =get around the problemSolution=Work in batches“We use the time it works to mass produce”TPM:A Lean Manufacturing MethodTPM and one-piece flow:Today:Objective=One piece flow Quality every timeMeans=TPM“We organize so it works continuously”10Goals of TPMnAchieve zero equipment breakdowns and zero defects through prevention.nEstablish prevention by Maintaining normal conditions Early detection of abnormalities Quick response 11Present ConditionsnOperators view machines as responsible for major productionnAnd limit their roles to equipment operation and inspecting for qualitynWhile maintenance workers view their function as responding to recurring breakdowns 12Maintenance ApproachesTime Based or Planned Maintenance-Periodically scheduled maintenance actions.Predictive Maintenance-Maintenance action performed resulting from evaluation of equipment condition.Corrective Maintenance-Maintenance action performed to restore optimal equipment function.Preventive Maintenance-A combination of Time based and Predictive Maintenance and actions taken to sustain optimal equipment performance and preclude breakdowns.13Early Equipment Management Optimizes equipment selection through:nEquipment Life Cycle Cost Analysis:analysis of the sum of all costs(direct and indirect)associated with an item of equipment throughout its period of use.n MP Design:activity which is focused on minimizing future maintenance costs and production losses of equipment at the design stage.14Total Productive MaintenanceWithout TPMWith TPMMED&Industrial EngineeringMaintenanceMED&Industrial EngineeringOperationMaintenanceThe operator operates,maintenance maintains,etc.Shared responsibilitiesOperation15Equipment Maintenance ResponsibilitiesOperationMaintenanceMED&Industrial EngineeringAutonomous maintenanceBreakdown maintenancePlanned maintenancePredictive maintenanceMaintenance prevention16Total Productive MaintenanceTPMEquipment in better working conditionDecrease of breakdownsDecrease of in-process adjustmentsOptimization of operation speedManufacturing defectsLead-timeQuality the first time17Performance Excellence:Expanding the Strategy through TPM IntroductionRole in Lean ManufacturingRole of the Operator in TPMAutonomous Maintenance ImplementationEquipment Performance:Measurement and Management18Total Productive MaintenanceTPM,the total approachnThe operator is the first line caretakernMaintenance personnel are the specialized caretakers.19Division of Maintenance Duties betweenProduction and MaintenanceDepending on knowledge and skills required,responsibility for equipment maintenance tasks needs to be defined:Maintenance TechnicianProduction Operator*Equipment overhaul*Basic lubrication*Special skill tasks*General cleaning*Complex adjustments*Multi-point inspection*High safety risk tasks*Basic adjustments20Maintenance Task Allocation betweenProduction and MaintenanceMaintenanceTechniciansProductionOperatorsAutonomous maintenance implementationVolume of maintenance tasks21Performance Excellence:Expanding the Strategy through TPM IntroductionRole in Lean ManufacturingRole of the Operator in TPMAutonomous Maintenance ImplementationEquipment Performance:Measurement and Management22Autonomous means“independent”Autonomous maintenance refers to activities involving operators in the maintenance of their own equipment.Autonomous Maintenance23Autonomous MaintenanceHow to make the operator more independent:nMake the documentation available(manual,maintenance schedule,log book).nAs a team,define manufacturing/maintenance/MED productive maintenance activities.nShow operator how to perform daily checks and take corrective actions.nTrain in basic operation,maintenance and defect detection techniques.nMake daily activities visiblenClearly identify items to supervise24Process Critical Machinery&EquipmentMap the process and identify critical equipmentTurningDrillingCuttingCleaningStripping&PaintingShipping25Adverse effects of inadequate cleaning26Adverse effects of inadequate cleaning:nFailure-equipment failure resulting from dirt and contamination affecting precisionnProduct defects-contamination of products or defects arising from insufficient cleaningnAccelerated deterioration-dirt and scale buildup shortening useful equipment lifenThroughput loss-reduction in output due to loss of operation speed due to grime and contamination.27Equipment DeteriorationNormal deterioration:deterioration that occurs despite correct use and maintenanceAccelerated deterioration:quicker deterioration occurring due to misuse in operation and neglect of maintenance.28PerformanceTimeEquipment Breakdown100%Time and Deterioration of PerformanceNeed for detection of performance decline29Cleaning as Detection of DeteriorationnCleaning-reduces accelerated deteriorationnPhysical contact with equipment-exposes abnormal operating conditions(i.e.vibration,noisy bearings,leaks,overheating,frayed belts,inoperative indicators,etc.)nPreventive action taken-extends useful life and avoids breakdowns30A good clean-up allows for a good inspectionNoiseVibrationHeatOilDirtQuickly detectAnd documentCleaning as Detection of Deterioration31 Factors Contributing to Equipment Failure:Equipment failuresLoose partsVibrationContaminationImproper/InadequateLubrication32 Eliminate Factors Contributing to Failure:Secure and tighten all fasteners,fittings,bolts and screws Replace any missing parts Replace any damaged,worn or wrong size parts Resolve all causes of leaks,spillage,spray and scatterImprove accessibility in order to accomplish Cleaning Lubricating Adjusting Checking33Total Productive MaintenanceSelf Maintenance-Operator_Equipment DescriptionI.D.#_Date:_Found by:_Description:Description:Total Productive MaintenanceSelf Maintenance-Maintenance_Equipment DescriptionI.D.#_Date:_Found by:_Autonomous Maintenance:Tagging Abnormalities34Tagging AbnormalitiesCleaning will uncover problems and undesirable conditions.Attach tag to make problem visibleResolves problems promptly and remove tags.Document plans to address those that cant be removed immediately.Autonomous Maintenance35Before Tags are Removed,Ask The 5“Whys”Problem:Oil leaks from the hydraulic press1.Why?Clogged filter2.Why?Oil was dirty3.Why?Metal filings got into oil4.Why?Oil fill cap missing5.Why?Misplaced&lostFind the root causeSolution!Oil filler cap attached to filler neck by a chain(Poka-Yoke)36Equipment Performance LossesnDowntime losses-time lost to equipment breakdowns,machine adjustmentsnEfficiency losses-time lost to start up and operating cycle speeds less than idealnDefect losses-time lost to machine related quality defects and recycling.37Equipment Performance Losses38Assignable Loss versus Common LossDefect rateTimeAssignable loss-corrected by restoring to original conditionsCommon loss-reduced by achieving optimal conditions39Importance of LubricationnSome experts estimate 60%of machine breakdowns associated with moving parts are due to lack of or improper lubrication practices.40 Lubrication Management?The need to lubricate equipment correctly and consistentlynaccording to usagenwith correct lubricantsnin the correct amountnat specified fittingsnat specified time intervalsnensuring coverage of contact areas41Visual Management of LubricantsGreenBlueOrangeRed w/White stripeOilGreaseHydraulic fluidSilicone42Maintenance ChecklistsTPM VERIFICATION LISTAt The Beginning of Each ShiftHydraulic Pressure Leaks(oil,fluids)Caps and hosesSwitchesLights and lampsBodyNoises/vibrationAt The End of Each ShiftCleanMake entry in maintenance book4312345678910Example Cleaning and Lubrication for Autonomous Maintenance44Basic Training in EquipmentnConduct equipment training for leaders.nLeaders then train group members.nOperators implement training to correct abnormalities and improve equipment performance.nImplement visual controls.45Example Skills MatrixBasic Training in EquipmentOperation102030405060Equipment typeSMDChip-shooter Cut&ClinchPin&BushingWave solderPost-Wave Wash David B.Linda W.Matt S.Debbie M.Steve H.John S.Jessica L.Legend:Knows basics Can do with help Can do w/o help Can teach someone elsePrinted Circuit Assembly Equipment Specialists46One Point LessonPurpose:nTo provide specific knowledge about a single topic of importance.nFacilitate team training in an easy manner.nDiscussed on the shop floor.Types:nKnowledgenImprovementsnSolutions to problems47Object Name:Fasteners Subject:IdentificationNumber:Generic typesDate prepared:4/17/00By:John ClarkApproved:Tina JonesOne-Point Lesson SheetDepartmentDate trainedNamePurpose:Identification of fastener hardware for repairs and ordering of replacements.Maint.PurchasingInventory StoresType:KnowledgeProblemImprovementxOne Point LessonProduction48TPM Deployment Effectiveness through Overlapping TeamsPlant ManagerStaff ManagerStaff ManagerStaff ManagerDept.ManagerDept.ManagerDept.ManagerSupervisorSupervisorSupervisorSupervisorOperatorOperatorOperatorOperatorOperatorMaximizing Communication&CoordinationTeam leaders49Build a Time Based Maintenance SystemDetermine equipment for time based maintenanceDevelop maintenance criteria and intervalsTrain for maintenance implementationExecute periodic maintenance Was maintenance effective?NoRevise maintenance instructions/parts provisioning50Establish an Equipment Failure DatabasenGather and manage equipment failure information.nAnalyze for trends and patterns of recurrence.nDevelop and issue periodic equipment failure summary reports.nInclude failure summary reports as a meeting agenda item for regular review,discussion and improvement action planning.51Predictive Maintenance as a Diagnostic Tool52Predictive Maintenance DeploymentDetermine equipment suitable for Predictive MaintenanceDevelop diagnostic methods and instructionsDiagnose equipment as definedExecute repair Repair/Overhaul Needed?YesRevise maintenance instructions/parts provisioningDocument repair informationEvaluate and revise diagnostic criteria53Maintenance Audits Audits are the most important factor in the successful implementation of an Autonomous Maintenance Program.They:nVerify success of implementation at each stepnProvide improvement feedbacknInstill a sense of achievement and reinforce continuing effort toward goals 54Maintenance Audits Implementation of autonomous maintenance group activitiesRequest for audit forwarded to TPM coordinatorAudit performedResults documentedPost audit meeting conductedAudit action items addressedPassedYesNoCongratulate TeamBegin implementation of next TPM activityExample Audit Cycle 55Performance Excellence:Expanding the Strategy through TPM IntroductionRole in Lean ManufacturingRole of the Operator in TPMAutonomous Maintenance ImplementationEquipment Performance:Measurement and Management56Overall Equipment Effectiveness Overall Equipment Effectiveness =Availability x Efficiency rate x Quality ratenAn index of the overall operating performance of equipmentnPoints to the need to Eliminate stoppagesIncrease operating speed.Improve quality(less defects,rework,scrap)57Equipment effectiveness measurementDowntime lossesEfficiency lossesDefect lossesAvailability=(Shift time-non-operating time)-downtime Shift time-non-operating timeQuality rate=Production quantity-defectivesProduction quantity Efficiency rate=measured production rate standard production rateEquipment breakdownsSet-ups and adjustmentsEquipment actual speed versus rated speedQuality defectsOverall Equipment Effectiveness=Availability x Efficiency rate x Quality rate 58Tracking Improvement Impacts On Overall Equipment EffectivenessBreakdown reductionsSet-up reductionsRework reductionsImproved equipment speedsDefect reductionsImprovement Activities59The Mission Board:A Roadmap to ActionMission BoardTeam Name _Leader:_Members:_ _ _ _Mission:_ _ _Targets:_ _ _ Solder Overall Wave Effectiveness AvailabilityEfficiencyQualityActions:_ _ _Evaluation:_ _ _Results:_ _ _60Maintenance Information Management System Maintenance Information Management SystemOverall Equipment EffectivenessCost accountingLabor&material costsMaterial ControlUsage and inventoryHuman ResourcesStaffing&skills requirementsQuality Assurance Product quality ProductivityMaintenance information in relation to other business process systems 61A Key Strategy In Pursuit Of World Class Performance62
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