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Total Productive Maintenance

What is TPM?

A process used to completely eliminate unplanned downtime in the manufacturing process; thus, improving the predictability of the manufacturing process, quality, delivery and cost.

Why do TPM?

Our goal is to create flow

Lost time interrupts flow

TPM eliminates wasted time due to machines’ downtime

Total Productive Maintenance (TPM)

Roadmap

Six Steps to TPM

Clean machine thoroughly

Eliminate and fix obvious problems

Use 5 Why’s to evaluate and fix the root causes of dirt

Agree on basic productive maintenance

As a team, perform basic productive maintenance and establish standard work for the process

Implement 5S in area surrounding the machine

Integrate this standard work into the cell’s standard work

Step 1 - Clean Machine Thoroughly Beginning:

Step 1 - Clean Machine Thoroughly Beginning:

Step 2 - Eliminate & Fix Problems - Red Tag Locations -

Step 2 - Eliminate & Fix Problems - Red Tag Locations -

Step 2 - Eliminate & Fix Problems - Red Tag Locations -

Results After Step 1 & 2

Results (After Step 1 & 2, pictures) :

Results (After Step 1 & 2) :

Results (After Step 1 & 2) :

Results (After Step 1 & 2) :

> 95% of oil leaks stopped (else waiting on

parts/service)

Savings: leakage of 1, 55 gallon drum of oil every

1-2 weeks (approx $8190.00 per year.)

Savings: Man-hours, clean-up materials, waste

material (approx $37000.00 per year.)

Operator to concentrate on production rather than

unplanned clean-up.

Create a weekly “Monitor & Lubrication” check sheet

Create a means to easily locate the specific location on machine

Provide pictorials and instructions, include:

Description of area

Type of lubricant to be used

Volume of lubricant to be used

Situation to perform operation

Step 3 - Agree on basic TPM (Overview)

CheckDaily check of oil level, air leaks and

oil leaks

CheckWeekly check edge liner fluid level

and filters

Spray UNWIND AND REWIND OP SIDE

SprayUNWIND AND REWIND DRIVE

SIDE

Spray PRINT STATIONS OP SIDE

Spray PRINT STATIONS DRIVE SIDE

Lube UNWIND AND REWIND OP SIDE

LubeUNWIND AND REWIND DRIVE

SIDE

Lube PRINT STATIONS OP SIDE

Lube PRINT STATIONS DRIVE SIDE

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TPM Checklist

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Step 4 of 6 – Establish Basic TPM

(Team Based)

Drive Side Unwind/Rewind Section Lube

Locations

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9

16

Top Chill Roller - Drive side

2 pumps of XYZ Grease

Lube while machine is Down

1 2

#2 Chill Roller - Drive side

2 pumps of XYZ Grease

Lube while machine is Down

Drive Side Unwind/Rewind Section Lube

Instructions

Drive Side Unwind/Rewind Section Lube

Instructions

Chill roll driver - Drive side

2 pumps of XYZ Grease

Lube while machine is UP

Rewind shaft - Drive side

2 pumps of XYZ Grease

Lube while machine is UP

3 4

SUN MON TUES WED THURS FRI SAT NUMBER CAUSE

DATE 31 1 2 3 4 5 6 1 ANILOX ROLLERS CLUTCH

CAUSE NO. 2 ANILOX ROLLERS TEETH

START

DOWNTIME3 DRIVE SYSTEM FOR ANILOX

END

DOWNTIME4 FRONT END HYD. (ARM LIFTS)

TOTAL

DOWNTIME5 BACK END HYD. (ORBIT MOTOR)

REPAIR TIME 6 BRAKE SYSTEM

REPAIRED

BY7 TENSION CONTROLLER

DATE 7 8 9 10 11 12 13 8 AIR SHAFTS

CAUSE NO. 9 CONTROL PANEL (ELECT)

START

DOWNTIME10 ADVANCE RETARD MOTORS

END

DOWNTIME11 IDLER/PATH ROLLER

TOTAL

DOWNTIME12 AIR SYSTEMS

REPAIR TIME 13 MISC ELECTRIC

REPAIRED

BY14 MISC HYDRAULIC

DATE 14 15 16 17 18 19 20 15 *OTHER (DEFINE AT BOTTOM)

CAUSE NO.

START

DOWNTIME

END

DOWNTIME

TOTAL

DOWNTIME

REPAIR TIME

REPAIRED

BY

DATE 21 22 23 24 25 26 27

CAUSE NO.

START

DOWNTIME

END

DOWNTIME

TOTAL

DOWNTIME

REPAIR TIME

REPAIRED

BY

DEFINE OTHER:

YEAR 2007JANUARY

KIDDER 2 MAINTENANCE RELATED UNPLANNED DOWNTIME

MONTHLY DOWNTIME CALENDAR

Step 6 of 6 – Integrate TPM

DOWNTIME VS REPAIR TIME(12 MONTH PERIOD)

0

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ANIL

OX R

OLL

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ANIL

OX R

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BACK E

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BRAKE S

YSTEM

TENSIO

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ONTR

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AIR S

HAFTS

CO

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PANEL (ELE

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ADVAN

CE RETARD

MO

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IDLE

R/P

ATH RO

LLER

AIR S

YSTEMS

MIS

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LECTR

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MIS

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YDRAU

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*OTH

ER (DEFIN

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CAUSE OF DOWNTIME

HO

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S

TIME DOWN

REPAIR TIME

Step 6 – Integrate TPM

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7

1

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NU

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OC

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ES

CAUSE OF DOWNTIME

DOWNTIME OCCURANCES(12 MONTH PERIOD)

Step 6 – Integrate TPM

Step 6 – Integrate TPM

Proposed Visual Location: