TPM - Augusto

8/8/2019 TPM - Augusto

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Kick outKick out TPMTPM implementation proposalimplementation proposal for 2008for 2008

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.

What is TPM?



Brief of Total Productive MaintenanceBrief 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).



TMPTMP DefinitionDefinition

The definition of Total productive maintenance changes from various

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

Stienbecker TPM is Ò Maintenance 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 notesImportant notes

(from New direction of TPM)

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 includesinvolvement 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 betweenmaintenance, 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

Corrective andpreventive

maintenance

activities

Normal operation of the

machine

Operate the machine correctly Operator

Set all machines adjustments correctly Operator

Maintenance routines

Clean, count and measure defects Operator

Perform machine lubrication Operator

Eliminate all looseness of the machine by tighten Operator

Perform PFM periodic task for operator inspection and

maintenance Operator

Perform PFM periodic task for technicians inspectionand maintenance

Technicians

Unscheduled activities

Perform all unscheduled maintenance activities andrepair machine breakdown

Technicians

Immediate detection of abnormal functionality of themachine and immediate report

Operator

Spare part andservice

availability

Right spare part stock inthe store and non stock

if required

Effective control of MRP and address PR releaseprocess

Store supervisor

Address all non stock parts in Ramis and PR releaseincluding service

Maintenance

Convert all PR into to PO and guaranteed that PO isreleased in all levels until it is sent to supplier

Procurement

Ensure that all spare part and services is delivered ontime in the plant

Procurement



Goal Objective Task description Responsibility

Predictive

maintenance

Machine reliability

Report, analyze and record of machine historical All team

Develop more accurate maintenance program.Continues revising of maintenance schedule

All team

Spare part consignment evaluationMaintenance and

procurement

Machine maintainability

Development of CBM Maintenance

Develop maintenance training plan for operators andtechnicians

All team

Ensure quality improvement in all maintenanceactivities

Maintenance

Perform long term maintenance plan (shutdown) andmachine upgrade

Maintenance

Rolls and responsibility



Are we ready to roll this program

proposal?

TPM - Augusto

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