T4S4-Successfully Deploying Total Productive Maintenance

8/8/2019 T4S4-Successfully Deploying Total Productive Maintenance

1/33

Suc c essfu l ly Deploy ing Tot a lProduc t ive Main t enanc e

Track 4 Session 4


2/33

2 0 0 7 M A T E R I A L H A N D L I N G & L O G I S T I C S C O N F E R E N C E S P O N S O R E D B Y H K S Y S T E M S

Copyright 2007 Productivity, Inc. All rights reserved

Eric D. Whit leyManufacturing Consultant

Productivity, Inc.

[email protected]

800.966.5423
mailto:[email protected]:[email protected]


3/33



Abs t rac t

This practical tutorial can help you makeimpressive gains in maintenance

effectiveness by applying the principles ofTotal Productive Maintenance. The goal ofthe TPM program is to markedly increase

production while, at the same time,increasing employee morale and jobsatisfaction. Regardless of your currentstrategy, the examples and approachesdiscussed will further your successtoward system reliability.


4/332 0 0 7 M A T E R I A L H A N D L I N G & L O G I S T I C S C O N F E R E N C E S P O N S O R E D B Y H K S Y S T E M S


Agenda

Introduction to TPM (Total ProductiveMaintenance)

Review the Five Pillars of TPM

Understand the Need For Autonomous

Maintenance.Takeaways & Questions




Int roduc t ion t o TPM




What Is TPM?

TPM is a plant improvement methodology whichenables continuous and rapid improvement of

the manufacturing process through the use ofemployee involvement, employeeempowerment, and closed-loop measurement ofresults.Nakajima, TPM Development Program: Implementing Total Productive Maintenance, ProductivityPress

Definition:

A companywide management philosophy, supported byinterlocking developmental strategies, to maximizeequipment effectiveness and eliminate equipment-related

waste




MAINTENANCE vs-

FIX/REPAIR Is maintenance value adding or non-value

adding?

What does maintenance produce that is

MORE valuable to you than the productitself?




Charac t er is t ic s o f TPM

Optimum relationships between peopleand equipment

Involvement of everyone, from topleadership to shop floor workers

A cross-functional approach, involving alldepartments

Implementation through small groupteamwork




Perfect Quality

TQMQuality at the Source

World Class Com pet i t iveness

Minimum Lead Time

JITWaste Elimination

Product/Service

People

EquipmentProcess

Management

Sustained Profitability& Customer Delight

Lean Management Systems

Continuous Improvement

Optimal Creativity and Utilization

Teamwork100% Participation in Improvement

Optimal Effectiveness

TPMMaintenance at the Source




TPM Is a Parad igm Shi f t

Old Attitude

I operate, you fix

I fix, you design

I design, you

operate

TPM Attitude

We are allresponsible for ourequipment, our

plant, and ourfuture




The Old Way vs . t he New Way

Engineers andmanagers areexperts; workersserve their dictates

Cost reduction comes

by driving labor out ofthe product andincreasing machine

utilization

Quick and dirtyoften has to be goodenough

Workers are experts;managers andengineers serve them

Cost reduction comesby speeding the

product through thefactory without waste

Do it right the firsttime you donthave time to do it over




Six Major Losses t o

Equipm ent Ef fec t iveness

Failures

Setup/changeover

and adjustments

Idling and minorstoppages

Reduced speed

Defects and rework

Startup loss


13/33



The Zero-Fai lu re Pr inc ip le

Hidden abnormalities

FAILURES

Wear, play, slackness,leakage, dust, dirt, corrosion,

deformation, adherence of rawmaterials, surface damage, cracking,

overheating, vibration, noise,and other abnormalities

A failure is the tip of the iceberg!

Expose hiddenabnormalities and

prevent quality andfunctional failuresbeforethey happen


14/33



The Five TPM Pi l la rs

Training andSkill Development

EarlyEquipmentManagement/Maintenance

PreventionDesign

AutonomousMaintenance

MaintenanceProcess

Improvement

SystematicEquipment

Improvement

TEAMS


15/33



Aut onom ous Main t enanc e

Wh t i A t


16/33



What is Aut onom ous

Main tenance?The ability of the machine operator to performdaily tasks to help with maintaining the

production equipment.The education of the operator with respect to

the functions and systems of the production

machinery.The release of daily tasks from maintenance

department, giving them the ability to focus on

more proactive maintenance measures.

Th 7 St f


17/33



The 7 St eps of

Aut onom ous Maint enanc e Initial cleaning and inspectionEliminate contamination

Establish provisional standards

Develop and train inspection standards

Inspect regularly and improve procedures

Workplace management

Participate in advanced improvementactivities


18/33



A View o f Equipm ent Losses

Lost availability,performance, and quality

Equipment poorly designed,maintained, or managed

Slight abnormalities

Sporadic lossesChronic losses

Unnoticed or ignored

Deterioration


19/33



Baby Gators Are Virtually Harmless


20/33



The gator is/was 18' 2" long.


21/33




22/33




23/33




24/33




25/33




26/33



Case St udy

Organization: Major Manufacturer of Industrialand Communications Wire and Cable.

Project Duration: >1 year; 3 Facilities. Client Project Objectives: Diffuse company-wide

Autonomous Maintenance effort and

internal Trainer Certification. Major Events:

4 TPM Leadership Training Workshops.

Facilitated >16 kaizen events. >150 employees Trained in Autonomous Maintenance.

4 Certified Autonomous Maintenance Trainers.


27/33



Case St udy

Aggregate Audited Outcomes: Facilityspecific include: Mean-time between

failures (MTBB) improved 48%, OEE from 48% to 55%,

wire breaks @ 5 per shift reduced

to 3 breaks in 3 months, numerous equipmentredesign projects. On-going project.


28/33



Case St udy

Organization: Large Chemical MiningOperation

Project Duration: 2.5 years. On-going.Client Project Objectives: Stabilize and Reduce

Maintenance Related Cost. Improve

Production Out-put.

Major Events:

TPM Action Planning Implement TPM/AM

Train-the-trainer 4 trainers certified


29/33



Case St udy

Aggregate Audited Outcomes:Maintenance Cost Stabilized. Production

Output Improved by 37%. $1.6M in Product Leaks

Eliminated (Documented Savings).

Boil-outs- Before 1 every 4 days Now 1 every17 days.

K T k


30/33



K ey Tak eaw ays

TPM is a plant improvement process thatincludes everyone.

The maintenance process should addvalue.

Poor equipment performance will hindermaterial flow.

Start by implementing Autonomous

Maintenance.

R d


31/33



Roadmap

R


32/33



Resources www.productivityinc.com

www.productivitypress.com

Autonomous Maintenance for Operators Author, Japan Institute of Plant Maintenance

TPM Development Program : Implementing Total

Productive Maintenance

Author, Seiichi Nakajima

Introduction to TPM Total Productive Maintenance

Author, Seiichi Nakajima
http://www.productivityinc.com/http://www.productivitypress.com/http://www.productivitypress.com/http://www.productivityinc.com/


33/33

Quest ions?

T4S4-Successfully Deploying Total Productive Maintenance

Documents

Transcript of T4S4-Successfully Deploying Total Productive Maintenance