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8/22/2019 TPM Kaizen
1/13
NONPROPRIETARYDOCUMENT
1
Finishing TPM Kaizen
Clean Sweeps
Hayes Lemmerz International, Inc.
Gainesville Operations
Nonproprietary
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Describe the ProblemDescribe the Problem11
Team Champion / Sponsor: Rafael AlvarezApprovals:Team Leader: Jeff Routzahn
Actual Completion Date:Expected Completion Date: 3-22-07
Output Boundary: Final InspectionInput Boundary: Machining
Metrics: % TPMs Completed for pretreatment, primer, liquid and clear coat systems.
Team Objectives: The objective of this team will be to analyze each TPM to verify that it is a value added TPM, write-up a description of
this TPM, how often this TPM must be completed, the time required to complete each TPM, what PPE is required to be worn, and to reviewfor other TPMs that might be value added but have not yet identified. Compliance to TPMs schedule is 100% obtainable each and everyweek.
Problem Statement: The finishing area has many production related TPMs set-up for maintaining equipment, dumping tanks, and generalcleaning of the paint system. Adherence to this program has been very difficult to maintain and the TPMs that are required have not beencompletely documented as to what needs done, how to do it, and the time required to do each TPM. We also have no operating
instructions that spell out what clothing should be worn during Paint Tech TPMs and system cleaning TPMs. When TPMs are notcompleted, rework and scrap increase for dirt and paint application issues, including paint drips, heavy clear and primer, etc. PMcompliance has averaged 46% in the last 4 weeks since we began painting again on 3 rd shift.
Customers: Final Inspection
Team Members: Samantha Turner, Dustin White, Gustavo #1 Menchacu, Bob Ribbit Kohler, and Lan Nguyen.
Project Start Date: 3-21-07Team Name: Clean Sweeps
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Describe the ProblemDescribe the Problem11
A systematic approach utilizing all employees through the
implementation of team based activities to achieve maximumequipment effectiveness by reducing operating costs.Goals of TPM:Zero accidentsZero defectsZero breakdowns
TPM
TOTAL PRODUCTIVE MAINTENANCE
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Analyze Historic Results/Analyze Historic Results/
Map Current ProcessMap Current Process22
TOTAL TPM
05
10
15
20
25
30
35
40
45
12-Feb 19-Feb 26-Feb 5-Mar 12-Mar
Due Complete
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Analyze Historic Results/Analyze Historic Results/
Map Current ProcessMap Current Process22PRETREAT TPM
0
2
4
6
8
10
12
12-Feb 19-Feb 26-Feb 5-Mar 12-Mar
Due Complete
PRIMER TPM
0
2
4
6
8
10
12
12-Feb 19-Feb 26-Feb 5-Mar 12-Mar
Due Complete
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Analyze Historic Results/Analyze Historic Results/
Map Current ProcessMap Current Process22
CLEARCOAT TPM
0
2
4
6
8
10
12
14
12-Feb 19-Feb 26-Feb 5-Mar 12-Mar
Due Complete
LIQUID TPM
0
1
2
3
4
5
6
7
8
9
12-Feb 19-Feb 26-Feb 5-Mar 12-Mar
Due Complete
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Analyze Historic Results/Analyze Historic Results/
Map Current ProcessMap Current Process22
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Identify & Prioritize Waste
33
Check Marks = CompletedCircled = Not Completed
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Evaluate Root Cause/
Identify Improvement Needs44
TPM not
Completed
on Time
Environment Methods
Material
Machines
Personnel
Lack of ownership by areas
Lack of priorities
Manning shortages
Unplanned downtime
Constant Machine breakdowns
Lack of tools to per form PMs
Not clear dir ection whenfacing a downtime situation
Weekly tasks confused withdai ly tasks
Lack of clear instructions
Lack of planning
High production demand
Firefigthing instead ofpreventing
Dirty environment
TPM FINISH - KAIZEN
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Document Activities/
Containment55
AA
3-27-07RoutzahnRevise Weekly PM List
3-23-07Ribbit, Samantha, JeffTPM procedures for Clear
3-23-07Ribbit, Samantha, JeffTPM procedures for Liquid
3-22-07Ribbit, Samantha, JeffTPM procedures for Primer
3-23-07Lan, Gustova, DustinTPM procedures for Pretreatment
3-22-07TeamReview and write TPM procedures
3-22-07TeamReview present paint TPMs
3-21-07RoutzahnWrite Charter for team
WhenWhoWhat
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Identify Countermeasures
55BB
3-28TurnerInstruct operators3-26RoutzahnPost new instructions in correct areas
3-26RoutzahnPost revised Weekly TPM Sheet
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Review PerformanceReview Performance
66
PM completion will be tracked on a monthly basis.
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