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1TPM - 12 Step Approach
TPM - 12 Step Approach
2TPM - 12 Step Approach
Definition of TPM
In early 70’s TPM focused on production sector aiming to maximize the equipment efficiency The new definition was set in 1989 aiming to create a corporate system that maximizes efficiency of production system
Classical Definition: Total Productive Maintenance
JIPM Defines it As :Total Perfect Manufacturing
Leading toTotal Production Management
Leading toTotal Profit Management
3TPM - 12 Step Approach
Effects of TPM
Effects of TPM always evaluated in terms of P - Production Q - Quality C - Cost D - Delivery S - Safety M - Morale
Intangible effects My Machine concept - First - Line operator owns the equipment Concept of Zero Clean Workplace
4TPM - 12 Step Approach
Philosophy of TPM
Basic philosophy of TPM is Prevention & Participation by all
departments & personnel, including top personnel to first-line
operators
Keeping the equipment in optimal condition with Visual control
Make a clean workplace
5TPM - 12 Step Approach
TPM & Concept of Loss
The concept of loss is basic to practicing TPM
TPM aims at elimination or reduction of losses
JIPM propounds 16 types of losses in manufacturing
environment i.e.
Equipment Efficiency related
Human efficiency related
Cost related
6TPM - 12 Step Approach
16 LOSSES
Equipment Efficiency
Availability Related
1 Break Down loss 2 Setup loss
3 Tool change loss 4 Start up loss
5 Planned Maintenance
Performance Related
6 Minor stops
7 Reduced speed
Defect Related
8a Scrap
8b Rework
7TPM - 12 Step Approach
Human efficiency
9 Management Losses
10 Operating motion Loss
11 Line Organization loss
12 Loss due to failure to automate
13 Loss due to Adjustment & Measurement
Cost Related
14 Yield Loss
15 Energy Loss
16 Die/Tool loss
16 LOSSES
8TPM - 12 Step Approach
OEE is the indicator of effectiveness of machine
A composite factor considering Availability, Performance &
Defect losses
It is tantamount to capability of equipment to deliver the
maximum possible good output
Overall Equipment Effectiveness
9TPM - 12 Step Approach
Step-wise implementation of TPM
Phases of TPM implementation Program
Phase 1 - Preparation for Launch
Phase 2 - Launch
Phase 3 - Execution
Phase 4 - Establish
10TPM - 12 Step Approach
Step 1 - Resolve to introduce TPM
Top person along with senior management visits TPM
practicing plants to see the effect of TPM
Declaration by top person determination to introduce
TPM at a gathering of managers, staff and all employees
Publicity to the event in company newsletter
Setting up an interim committee to organize for TPM
introduction
11TPM - 12 Step Approach
Introduction of TPM without proper training and education can
lead to failure of the movement
Organizing TPM awareness seminars for employees
Poster and slogan contest
Publishing articles on TPM in company newsletter
Plant visits to TPM practicing companies
Step 2 - Introductory education and campaign
12TPM - 12 Step Approach
Step 3 - TPM Promotional Organization & Model Machines
TPM is an activity which requires constant facilitation and
tracking till a critical mass is achieved
A full time promotional office called as “TPM Secretariat” is
formed
People who are trained as TPM Facilitators are part of this
secretariat
Steering committee is formed consisting of senior plant
personnel
13TPM - 12 Step Approach
Step 3 - TPM Promotional Organization & Model Machines
Plant in-charge is the chairman of TPM steering committee
Senior level manager is made in-charge of the secretariat
Specialized sub-committees are formed headed by senior
person from the relevant area with representation from each
department
14TPM - 12 Step Approach
Model Machine Activity
Each unit selects a model machine/equipment Manager
alongwith his engineers and staff work on the machine to
Do initial cleaning
Identify sources of contamination
Take measures for containing the contamination
Do Kaizens to reduce the losses
Model machines are showcased to all the employees as proof
of TPM’s effectiveness
15TPM - 12 Step Approach
Step 4 - Setting TPM Policy and Targets
TPM is not the goal but means to achieve the goals
Data on Benchmarks - benchmark is the status at the start
of activity
Stretched targets are set for each of the item
Timelines are fixed within which targets are to be achieved
Master plans are made for each sub-committee
Tracking of progress is done wrt the master plan
16TPM - 12 Step Approach
Master Plan is prepared to create a schedule for all the 12
steps upto the stage of PM award qualification
Master Plan talks about major activities such as- formation
of sub-committees, their start date and end date etc.
Each sub-committee makes its own master plan
Step 5 - Preparation of Master Plan
17TPM - 12 Step Approach
Step 6 - TPM Kick-Off
TPM Kick -Off is a memorable occasion in the TPM journey
TPM is launched plant-wide with involvement of all employees
Launch function is at a grand scale attended by employees,
suppliers, dealers and crème - de- la - crème of the company
Top person addresses all the employees
TPM organization structure, TPM policy and targets are
announced
Union representatives commit employee support to TPM
activity
Presentations are made by Model machine teams to exhibit the
success of TPM activity on model machines
18TPM - 12 Step Approach
Step 7 - Program for improving OEE(KK, Tools,JH,PM, & E&T)
Kobetsu Kaizen (Focused Improvement)
Focuses on Increasing Production & reducing cost
Reducing manpower and maximising output per person
Cross functional teams take up projects to eliminate/reduce
losses in the system
19TPM - 12 Step Approach
Tools Sub-Committee
Tools focus is on
Eliminating Production Loss due to non- availability of tools
Reducing Tool Cost by
Reducing Tool Inventory
20TPM - 12 Step Approach
Methodology
Maintain bank and crib inventory levels based on
consumption pattern and lead time.
Achieve price reduction through
Import substitution
Reduction in prices ( where same tool is supplied at
different rates)
Absolute price reduction
Variety reduction and hence price reduction
Alternate cheaper source
21TPM - 12 Step Approach
Methodology
Achieve enhancement in tooling life through
Change in material
Change in design
Change in process
Surface treatment such as coating
Recycling and or salvaging
Identify non moving tools and tooling and take action for
disposal
22TPM - 12 Step Approach
Jishu Hozen (Autonomous maintenance)
70% of equipment failures are due to forced deterioration.
JH focuses on elimination of forced deterioration caused
by abnormalities like splashing of oil / coolant, ingress of
machining chips on machine elements, settling of dust on
electronic parts, exposure to heat, vibrations etc.
• Through “Individuals preserving their own equipment”
• By carrying out routine inspection, oiling & re-tightening
/small repairs
Jishu Hozen
23TPM - 12 Step Approach
1S is Seiri in Japanese language which means remove unwanted material from work place and dispose it off.
2S is Seiton in Japanese language which means place for everything and everything in it’s place. There is orderly arrangement of required material.
After doing 2S, we can retrieve the required tooling in single touch pickup,in few seconds.
Step - 0 (1s & 2s)
24TPM - 12 Step Approach
Implementation of 1s-2s
Formation of circles
Allocate areas to each circle
Training to all Circle members
Start 1S,2S movement
Start Pick up movement
Change to ‘’No drop’’ movement
Maintain shop floor neat & clean
Sustain
25TPM - 12 Step Approach
Step 1
Dis cover to discover
Discover by cleaning
Cleaning for inspection
Inspection for repairs of malfunction of equipment.
Discovery of areas where cleaning / inspection /
lubrication is difficult
Audit by Unit Head
Jishu Hozen
26TPM - 12 Step Approach
Step 2
Eliminate source generating dirt/dust oil etc.
Improve the places of hard to access for cleaning,
lubricating and inspection to shorten the time required
for the above
Passing of the audit
Cleaning / inspection / lubrication time reduction
Break down reduced by 50 %
Machine clean without cleaning
Jishu Hozen
27TPM - 12 Step Approach
Step 3 Basic condition of activities to prevent equipment deterioration. (Cleaning, lubrication, tightening) Create visuals & write standards e.g.
• Levels• Looseness• Tension• Lubrication• Gaps / clearances.• Vibration.• Noise• Temperature• Pressure
Jishu Hozen
28TPM - 12 Step Approach
Planned Maintenance
Planned Maintenance
Achieve Zero breakdown
Focus is on addressing natural deterioration
Supports JH to tackle forced deterioration
Aims at drastic reduction in Repair & Maintenance Cost by
improving service life of parts and reducing time to repair
29TPM - 12 Step Approach
Methodology
Step 1: Ranking and support to JH
Step 2: Define role of operation division & Maintenance
division
Step 3: Zero Breakdown activity
Breakdown classification using why why analysis
Implement cause side countermeasure
Use of PM inspection & MTBT concept
Implement TBM activity
Implement CBM
30TPM - 12 Step Approach
Methodology
Step 4: Corrective maintenance
Step 5: Maintenance MIS
Step 6: Reduce Maintenance cost
Step 7: E & T support
Step 8: MP activity
31TPM - 12 Step Approach
Maintenance activities
Improvement activities
Preventive
Da
ily J
ish
u H
oze
nM
AIN
TE
NA
NC
E P
RE
VE
NT
ION
Break down
Periodic Predictive
(TBM) (CBM)
C rank machine
Single bulb change of OHP Keep stock of
spares
Corrective maintenance
Maintainability Reliability
MTTR MTBF
Planned Maintenance
32TPM - 12 Step Approach
Education & Training
Education & Training
Focus on fostering excellence in Skill, Attitude and ability
Eliminating breakdown, defects and accidents due to poor
skill & knowledge
Improving knowledge of operators & maintenance
mechanics about equipment / components
Promoting participation of all
33TPM - 12 Step Approach
4 Quadrant Skill Matrix Approach
Classification of operators & technicians
Defining skill requirements
Preparation of syllabus and training material
Pre-training test
Developing training calendar
Organizing training programs
Post training evaluation
Recording of competency levels
Feedback and continuous review
Methodology
34TPM - 12 Step Approach
Specific Training Modules
Loss based training
Cost awareness
JH Step 4 on various machine subsystems such as -
Hydraulics, Pneumatics, Nuts and Bolts, Drives etc.
Maintenance technician training
35TPM - 12 Step Approach
Promoting TPM through events
Best JH Step 4 machine contest
Kaizen conference
TPM quiz
Best Visual Control
TPM Newsletter
36TPM - 12 Step Approach
Development management focuses
To procure ‘maintenance free’ equipment by incorporating
the improvements at the development stage of new
equipment
To establish system for ensuring reliability, maintainability
operability & Jishu Hozenability
To incorporate the improvements emanating from various
Kaizens related to KK, JH, PM etc. into the new equipment
Objective is to get easy - to - use facilities
Step 8 - Development Management
37TPM - 12 Step Approach
Step 9 - Establish Quality Maintenance System
Quality maintenance focuses on
Setting conditions under which no defects will be
generated
Less emphasis on measuring and maintaining the quality
characteristic of the job
Emphasis on controlling the cause side parameters
To achieve the goal of Zero Defect, Zero rework and Zero
Customer complaints
38TPM - 12 Step Approach
Step 1
Gap analysis
Stratification
Step 2
Develop QA matrix
Step 3
Identify 4 M conditions
Step 4
Defect classification (a/b/c type)
Why Why analysis
PM analysis
Methodology
39TPM - 12 Step Approach
Step 5
Implement Poka yoke/ kaizen / countermeasures
Set 4 M conditions
Derive Q components
Step 6
Prepare cause side checklist
Step 8
Standard operating procedure
Step 9
Provide specific training to engineers / machine operators
Methodology
40TPM - 12 Step Approach
Step 10 - Improvement in Indirect Departments
This team focuses
Reducing cost of buying of incoming material
Optimizing material inventory
Ensuring implementation of 1S,2S across entire plant
Achieving optimum utilization of manpower
41TPM - 12 Step Approach
Methodology
Material cost reduction is achieved through 16 criteria
approach
Price reduction
Taxation
Value engineering
Packaging
Handling & transportation etc.
42TPM - 12 Step Approach
Job analysis under
Job elimination
Job clubbing
layout changes
Reduction in mudas
Methodology - Optimum Manpower Utilisation
43TPM - 12 Step Approach
Step 11 - Establish system for Safety Health & Environment preservation
Focus on building shop-floor which is -
Clean ,Bright & Safe
This is achieved by eliminating tasks which are -
Dirty ,Difficult & Dangerous
Aim is to achieve
Zero accident
Zero pollution
Zero health hazards
44TPM - 12 Step Approach
Change in attitude Listening
No doubting
Doing
Change in thinking style We can achieve ZERO
Forget the past glory
Not enough
Change in Culture Working together
Commitment of all
Involvement of workforce
Happy and Motivated employees
Ready to face challenges &
Satisfy changing customer needs
Leading to
Leading to
Leading to
Intangible benefits
45TPM - 12 Step Approach
Step 12 - PM award qualification examination
After establishing framework for TPM implementation
and achieving the results in each area, the plant appears
for PM award by JIPM
Pre-assessment audit
Final certification audit
Culminating the part I of TPM journey with
‘TPM Excellence Award”
46TPM - 12 Step Approach
Beyond 12 Steps…...
12 Steps are part I of TPM which lays the foundation of
TPM movement in any organization
In part II objective is to reinforce and spread the movement
deeply and widely towards the ultimate goal of world class
manufacturing
TPM is an ongoing journey encompassing the entire company
for a cultural transformation in pursuit of excellence