ANAND U 1
TPM Basic AwarenessandAutonomous Maintenance
ANAND U 2
A Brief History-TPM
BreakdownMaintenance< 1950
PreventiveMaintenance1950 - 1970
CorrectiveMaintenance1957 - 1978
MaintenancePrevention1960 - 1980
Total ProductiveMaintenance
1971 - Present
ANAND U 3
Meaning of T-P-M
T - TOTAL•Total Efficiency Maximisation•Total Lifecycle of Production System•Total Manpower Coverage
P - PRODUCTIVE Productivity Maximisation by :•Zero Accident•Zero Defect•Zero Breakdown
M - MAINTENANCEMaintenance Covers Life CycleOf Prod. System:
•Individual Processes•Plants•Prod. Management System
ANAND U 4
Pillars of TPMFo
cuss
edIm
prov
emen
t
Auto
nom
ous
Mai
nten
ance
Plan
ned
Mai
nten
ance
Educ
atio
n &
Trai
ning
Early
Equ
ipm
ent
Man
agem
ent
8 Pillars of TPM
(1989 – Present)
Qua
lityM
aint
enan
ce
Indi
rect
Depa
rtmen
t
Safe
ty &
Env
iron.
Man
agem
ent
ANAND U 5
Calculating Equipment Loss
Overall Equipment Efficiency
= Operating Rate X Performance X Rate of Efficiency Qlty Prdts.
OperatingRate
PerformanceEfficiency
Rate ofQuality Pdts.
Function of Total Time VsDown Time :
•Scheduled•Planned Mtn•B/Down Mtn•C/Over•Tool Change
Function of Std. Cycle Time Vs. Actual Cycle Time:
•Operation Stability•Minor Stoppages
Function of Good O/Put Vs. Defective O/Put :
•Rejections•Rework
ANAND U 6
Calculating Equipment Loss
Overall Equipment Efficiency
= Operating Rate X Performance X Rate of Efficiency Qlty Prdts.
OperatingRate
PerformanceEfficiency
Rate ofQuality Pdts.
87% 50% 98%
OEE = 43 %Goal : > 85%
ANAND U 7
Seven Big Losses
Brea
kdow
n
Defe
cts
Min
or S
topp
ages
C/O
ver &
Adj
Tool
Cha
nge
Red
uced
Spe
ed
Star
t-up
Loss ---
------
--- C
umul
ative
% --
------
------
100 %
0 %
ANAND U 8
Types of Deterioration
Natural Deterioration
ForcedDeterioration
Ageing under Standard Operating Conditions
Artificially Accelerated because of Non-Standard
Operating Conditions
Breakdown Attracts Breakdown !
ANAND U 9
Basic Approach to Zero Breakdown
•Breakdowns Occur !•Equipment Fails !
•Zero Breakdowns !•We will not Cause Equipment Failure !
Breakdowns !
Hidden Defects
•Dust / Dirt•Abrasion, Play, Looseness. Leakage•Corrosion, Scratches, Deformation•Temp, Vibration, Noise
Anand
•Physical•Psychological
ANAND U 10
Transformation – Phase 1
Operator : Possess ability to do Self Initiated Maintenance
Maintenance Person : Possess ability to do Maintenance on all types of Equipment
TSG : Possess ability to do design such equipment that require no maintenance
ANAND U 11
A set of activities for restoring equipment to its optimal condition and changing the work environment to maintain those conditions through daily maintenance activities.
Definition:
ANAND U 12
To restructure the corporate culture through behavioral changes and equipment improvements.
TEARDOWNTHE WALL
Objective:
ANAND U 13
To upgrade the capabilities of all company members through education, training, and participation.
Intent:
TPM
ANAND U 14
L O S S
To identify productivity losses and involve all members of the company in loss elimination programs.
Purpose:
ANAND U 15
What Are The Benefits ?
Safe Work Environment
Job Security
Improved Quality
Increased Productivity
Improved Skills
ANAND U 16
What Can Be Expected?
Productivity:Value added improvement 1.5 to 2 times.40% reduction in breakdowns.Overall equipment efficiency up 1.5 to 2 times.
Quality:Reduction in Work-In-Process (WIP) defects.Reduction in Parts Per Million (PPM).
Cost:Production costs reduced by 30%.Quality cost reduced by 30%.
ANAND U 17
What Can Be Expected?
Safety & Morale:Zero accidents.5 -- 10 suggestions per employee.
Education:Skill upgrading of employees.
Delivery:Reduced finished goods inventory by 50%.100% on-time delivery.Reduced premium freight by 60%.
ANAND U 18
Equipment Failure Statistic
Other Equip. Failures
43%
Dirt12%
Lubrication Method13%
Lack Of Lubricant
24%
Source: JIPM
Loose Parts8%
Autonomous Maint.Role in B/D Reduction
Cleaning
Lubrication
Inspection
Tightening
ANAND U 19
Overview of Eight Pillars
ANAND U 20
Pillar : Planned maintenance
Aim : Realise efficiency in maintenance department to eliminate 8 major losses
Method: Daily maintenanceTBM, CBM, Improvement for increasing the service
life expectancy, control for replacement of parts, failure analysis and prevention of re-occurrence, Lubrication control
Who : Operator and maintenance men
ANAND U 21
Pillar : Focused Improvement
Aim : •To focus on specific losses & Increase productivity, ease of operation & Standardization of methods•To ensure adequate methods for identification of losses & countermeasure implementation•To increase ease of detecting / correcting deterioration of equipment
Method: Repeated Equipment Breakdown Analysis & Countermeasures, CAP-Do for Minor Stoppages, CAP-Do for Change-over, CAP_Do for Defects
Who : Operator and Technical Services Group
ANAND U 22
Pillar : Education and training
Aim : Raise the technical skill level of operators and maintenance men
Method: Basic maintenance steps- nuts & bolts - key mating - Bearings- Gear Transmission- Leakage prevention- Hyd & Pneumatic eqpt -Electrical control systems
Who : Operators and maintenance men
ANAND U 23
Pillar : Initial flow control
Aim : Shorten the trial period for new product, design of new equipment, and run-up time for stable launching of products
Method: •Set forth development and design targets•Easy to manufacture, maintain and reliable equipment•Study of LCC•Review of design methodologies
Who : R & D / Production Engg Staff
ANAND U 24
Pillar : Quality Maintenance
Aim : Realise ‘Zero’ defects through observing the required equipment maintenance
Method: Conformation to the standards for quality characteristics and recognise the defect symptom and actual defect record. Assure product quality, investigate the unit process material and energy utilisation eqpt condition and production methods. Investigation, analysis and kaizens for fuguai conditions . Set forth 3 M conditions and inspection reference values. Standardisation of the rules to be observed and trend control
Who : Staff and cell leaders
ANAND U 25
Pillar : Safety
Aim : Attain and keep the Zero accident levelCreate a healthy and clean working area
Method: Safety measures to protect the operators from equipment accidentsMake the operation safeImprove the working environment - noise, dustMeasures to achieve environment protection.Attention to the health and hygiene of the employeesPromotion of cheerful working environment.
Who : Managers & staff
ANAND U 26
Pillar : Office TPM
Aim : Realise Zero functional lossOrganise high efficiencyRender service and support function to the service
departments
Method: By 5 pillar activities
Who : Members of sales and administrative departments
ANAND U 27
TPM General Master Plan
Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8 Q9 Q10
Q11 Q12 Q13INTRO TRAINING
PILOT M/C
CRI. M/C -S1CRI. M/C –S2
CM–S3
IMPORTANT M/C –S1 / 2 / 3S4
ALL M/C –S1 / 2 / 3DATA MGT.
TPM DATA MONITORING ON EACH LINE
ANALYSIS OF B/DOWN & MINOR STOPS
IMPROVEMENT FOR CHANGE OVERANALY. CHRONIC LOSSES
BREAKDOWN ANALYSIS
IMPROVE WEAK POINT PARTS
ESTABLISH PM STANDARDS
PREDICTIVE MAINTENANCE
Self Maintenance
Individual
Improvements
Planned Maintenance
Kick off TPM Award
ANAND U 28
Understanding Losses
ANAND U 29
16 Major LossesWhich Obstruct Production Efficiency
5 Major Losses Obstructing Manpower Efficiency
3 Major Losses Obstructing Material & Energy Utilization
8 Major Losses Obstructing Equipment Efficiency
ANAND U 30
5 Major Losses Obstructing Manpower Efficiency:
1. Management Loss
2. Operating Motion Loss
3. Line Organization Loss
4. Logistics Loss
5. Measurement & Adjustment Loss
16 Major Losses - Continued
ANAND U 31
3 Major Losses Obstructing Material & Energy Utilization:
1. Energy Loss
2. Die, Tool, & Fixture Loss
3. Material Loss
16 Major Losses - Continued
ANAND U 32
1. Equipment Failure Loss: Largest failure of all losses. Two types:a. Function-Stoppage: Failure occurs unexpectedlyb. Function-Deterioration: Decreases over time
2. Set-Up & Adjustment LossSet-Up: Losses due to changeoverAdjustment: Minor process adjustments
8 Major Losses Obstructing Equipment Efficiency:
16 Major Losses - Continued
ANAND U 33
3. Consumable Parts Change Loss: Weld tip, weld liners, cutting bits
4. Start-Up Loss: Equipment warm-up and stabilization
5. Minor Stoppage & Idling Loss: Losses we have a tendency to “put up with”
- part hanging- pushing re-set button
8 Major Losses Obstructing Equipment Efficiency:
16 Major Losses - Continued
ANAND U 34
6. Speed Loss: Slowing the equipment down to produce good quality
7. Defect & Rework Loss: Time and manpower lost in both types
8. Shutdown Loss: Planned stoppage of equipment
16 Major Losses - Continued
8 Major Losses Obstructing Equipment Efficiency:
ANAND U 35
AutonomousMaintenance
ANAND U 36
Autonomous Maintenance
Purpose: Prevent equipment from forced deterioration Keeping one's own equipment in good condition by
oneself Members:
Operator, Cell Coordinator Activities:
Initial cleanup Countermeasure for HTA & SOC Creation of autonomous standards for equipment Daily CLIT activity Training of operators proficient in equipment Adequate compliances with basic and usage
requirements of equipment
ANAND U 37
Autonomous Maintenance
Activities where each operator performs timely inspection, lubrication, consumable parts replacement, repair, troubleshooting, accuracy checks, etc. . . . . on their own equipment.
ANAND U 38
The Goal Of Autonomous Maintenance
Keeping one's own equipment in good
condition by oneself.
ANAND U 39
Types of Deterioration
Natural Deterioration
ForcedDeterioration
Ageing under Standard Operating Conditions
Artificially Accelerated because of Non-Standard
Operating Conditions
Breakdown Attracts Breakdown !
ANAND U 40
Basic Approach to Zero Breakdown
•Breakdowns Occur !•Equipment Fails !
•Zero Breakdowns !•We will not Cause Equipment Failure !
Breakdowns !
Hidden Defects
•Dust / Dirt•Abrasion, Play, Looseness. Leakage•Corrosion, Scratches, Deformation•Temp, Vibration, Noise
Anand
•Physical•Psychological
ANAND U 41
ActivitiesPerformed By The
Operator
Prevent Deterioration
MeasureDeterioration
Restore Deterioration
ANAND U 42
PreventMachine
FromDeteriorating
ImproveWeak
Points InDesign
EstablishBasic
Conditions
KeepOperationConditions
Operators Maintenance
Management
TPM Roles Of
ImproveSkill
ANAND U 43
Initial Cleanup
Countermeasure for HTA & SOC
Prepare Temporary Standard
General Inspection
Autonomous Inspection
Standardization
Autonomous Maintenance
Seven Steps ofAutonomous Maintenance
ANAND U 44
AM Step Zero Preparation for Step 1
Safety education about equipment Basic knowledge about machine
structure Arrangement of cleaning material Arrangement of white and red tags
ANAND U 45
ANAND U 46
ANAND U 47
Machine / Lock Photo
ANAND U 48
AM Step One
Initial Cleaning
ANAND U 49
Initial Cleaning
Take pictures to show “Before Conditions” Safety first Thoroughly clean dirt accumulated over
years Open covers and guards to clean inside Also clean the environment around the
equipment Cleaning becomes a normal part of the
operator responsibility
Cleaning is Inspection
ANAND U 50
Attach tags to problem locationTags to be filled out by all operatorsEach problem requires its own tagWhite TAG -- Operator responsible to repairRED TAG -- Maintenance group responsible for repairs
TPM
Initial Cleaning – Continued......Cleaning is Inspection
ANAND U 51
TPMAutonomous MaintenanceStep. No.
Problem Found Here1 52 3 4
Equipment::Asset No.:Date Found:Found By:Description of Problem:
Page 1
REMOVE THIS SHEET AFTER ATTACHINGTAG AND USE IT AS COPY
TPMAutonomous MaintenanceStep. No.
Problem Found Here1 52 3 4
Equipment::Asset No.:Date Found:Found By:Description of Problem:
Page 2
ATTACH THIS SHEET TO EQUIPMENT
TPM Tags
ANAND U 52
Tag History
Upon completion of the repair, log or file tags for future reference.Keep the information at the cell.Red tag history highlights:
Recurring problems Repair history Maintenance response
White tag history highlights: Operator repairs and minor stoppages Recurring problems that need to be red tagged
ANAND U 53
Things to Look for During Cleaning
Looseness Breakage, Deformation, Crack Wear & Tear Play, Slack Misalignment Poor soldering Poor wiring Rust Contamination Oil leaks Unwanted parts
ANAND U 54
AM Step Two
Counter Measures for Hard-to-Access& Source of Contamination
ANAND U 55
1. Relocate for better access2. Plexi-glass covers3. Windows or guards4. Fill unused or unnecessary
holes/groove
Note: Always use approved and permanent countermeasures.
Countermeasures For Hard-to-Access Areas
ANAND U 56
Eliminate Sources That Make The Equipment Dirty.
1. Repair or tag leaks2. Create ways to remove slag, shavings etc.3. Use filters where necessary4. Check for exhaust fan possibilities5. If the source can not be eliminated, contain the source, until it is eliminated
Note: Always use approved and permanent countermeasures.
Countermeasures For Source of Contamination
ANAND U 57
Steps In Preparing A Temporary Guard
12
3
Improvement
Observe Line
Think Of A Way To Control The Source Of Contamination
Make A Model Using Corrugated Cardboard
Try
Fabricate Temporary Device Using Galvanized Steel Or
Other Material
Produce Final Device
Suggest As Standardization And
Future Design Information
ANAND U 58
Hard-To-Access & Source Of Contamination Areas
Equipment Name:____________________
Asset No.:____________________
PageNo.:____________________
Type Item
Cleaning, Lubrication, Inspection
Counter-measure
WhoFound
WhoResponsible
Completion
HTA SOC
DescriptionOf
ProblemTarget Actual
ANAND U 59
AM Step Two: Benefits
Contamination is stopped at source. Contamination is controlled/
minimized . Access is improved to areas that are
difficult to Clean, Lubricate, Inspect and Tighten.
Time taken for CLIT activities is reduced.
ANAND U 60
AM Step Three
PreparationOfTemporary Standard
This step is to enhance the equipment reliability & maintainability
ANAND U 61
What items need to be check. Who will perform the check. Where the location is to be checked. What to use for the inspection or cleaning. Target time to complete the task.
Temporary Check Sheet for CLIT
ANAND U 62
Temporary Standard - C L I T Sheet
S N
What Item What to do How When Who Target Time
1 Outer Portion of Motor and Pump
Cleaning Hand Daily Operator 2 Min
2 Foundation Bolt
Check whether properly Tight
Hand Daily Operator 1 Min
3 Belt Tension Proper Hand Daily Operator 1 Min
4 Leakage No leakage Visual Daily Operator 2 Min
5 Crank case Check oil level Visual Daily Operator 1 Min
6 Pulley, Guard and Belt
Cleaning Hand Weekly Operator 5 Min
7 Pulley Guard Check whether proper tight
Hand Daily Operator 1 Min
8 Complete Pump
Functioning Properly
Visual Daily Operator 2 Min
Autonomous Maintenance – Step 3
Total Time Required – Daily 10 minutes and additionally weekly 5 minutes
ANAND U 63
Gauges should be marked for high and low operating ranges
Points of lubrication should be marked and color coded for quick, accurate
identification
Visual Control to Support AM Step 3
ANAND U 64
Visual Control to Support AM Step 3
ANAND U 65
Equipment Failure Statistic
Other Equip. Failures
43%
Dirt12%
Lubrication Method13%
Lack Of Lubricant
24%
Source: JIPM
Loose Parts8%
Autonomous Maint.Role in B/D Reduction
Cleaning
Lubrication
Inspection
Tightening
ANAND U 66
One Point Lesson
Tool to convey information regarding knowledge and skill of equipment, and about trouble/improvement cases.
Designed to help enhance knowledge and skill in a short period of time at just the right time whenever required.
To upgrade the level of expertise of whole circle.
To encourage every member to think, study and prepare OPL and teach to all the team members.
ANAND U 67
One Point Lesson
Correct usage of part of equipment Generating sources Difficult to access location Structure and function of machine Inspection method
ANAND U 68
Cooperation Between All Departments
Maintenance understanding and support
Led By Work Teams
Operator Input and Decision on Check Sheet Items
TPM Activities Become Part Of The Daily Routine
Key Points For Success In Implementation
ANAND U 69
Transmission Of Education One Point Lesson Sheet
Standardization Activities Board:
Timing Chart One Point Lessons
# Of Equipment Failures Defect Rate# Of Minor Stoppages Current Step In ProgressChangeover Time Problem Tag Data"Before" & "After" Pictures Downtime DataClean-up Time Equipment Check TimeMaintenance Costs Accidents
Key Points For Success In Implementation
ANAND U 70
Quick Repair TPM Meetings Step System Step Audit Promote Success Stories
Key Points For Success In Implementation
ANAND U 71
Autonomous Maintenance Audit
Upon completion of each step, the work teams will request an audit of the step just completed.
This audit will allow managers to confirm whether the Autonomous Activities are being followed to their intent.
ANAND U 72
AM Step Four
General Inspection
ANAND U 73
This Trg Helps in
Doing Self Maint.
This Trg Helps in
Doing Self Maint.
This is forProduction
OEs
This is forProduction
OEs
This is a 3 Days
Program
This is a 3 Days
Program
This isAvailable
At Anand U
Pune
This isAvailable
At Anand U
Pune
This is Trg for
AM Step 4
This is Trg for
AM Step 4
Machine Mechanism
Training
Machine Mechanism
Training
ANAND U 74
AM Step 4 – General Inspection
This is three days training module conducted by Anand U Pune Team.
This consist of basic knowledge of Electrical, Electronics, Hydraulics, Pneumatics, Bearing & Lubrication, Fasteners and Power Transmission Devices.
How to do day-to-day maintenance of machine elements.
Dos and Don’ts of machine operation.
ANAND U 75
General Inspection
ANAND U 76
SN Name Hydraulics
Pneumatic
s
Electrical
1 Ashok
2 Mohan
Skill Assessment
ANAND U 77
1
2
34
5
6
7
3
bar
Pressure gauge
Water Oil
1
2
34
5
6
7
3
bar
Machine Mechanism Training
Lubrication
Fasteners Electrical
Pneumatics
Hydraulics
OperatorsSkill
&Knowledge
ANAND U 78
Lubrication:•What to lubricate•When to lubricate•Types of lubricants for each point•How to lubricates•Cleanliness of lubricants
Hydraulics:•Hydraulic oil level•Room temp.•Pressure•Relief valve•Pump•Filter•Leakage
Elect & Electro•Current•Voltage•Loose connections•Equipment safety•Self safety
Pneumatics:•Air pressure•Air filter•Regulator•Lubricator•Drain point•Air leakage
Regular Inspection
of Machine
Use of Five Senses:•Abnormal Sound•Vibration•Excess Heat•Abnormal Smell
ANAND U 79
Supervisor / Cell Leader
Operator
SubjectFaculty
MaintenanceTeam
Training Programby
ANAND U 80
Operators’ Training
MachineMechanism
Training
ProcessTraining
Common M/CElements
Specific M/CElements
ANAND U 81
ElectricalBearing &
Lubrication
PneumaticsProximitySensors
Fasteners
Hydraulics
Topics Identified
For
Training
Drives Safety
ANAND U 82
Fasteners
ANAND U 83
ANAND U 84
AM Step Five
Autonomous Inspection
ANAND U 85
Autonomous Inspection
Draft autonomous inspection check sheet (Formal/Final Jishu Hozen Standard) for Cleaning, Lubrication, Inspection and Tightening of equipments.
This final standard will be based on tentative standard drafted during AM step 3.
Consider the results of AM step 4, in drafting final Jishu Hozen standard.
Clarify and define the role of production and maintenance department in preventive maintenance of equipments.
ANAND U 86
..
Role of
Prod.
Roleof
Maint.
•Improve operator’s skill of equipment inspection and operation.
•Ensure adequate compliances with basic requirements.
•Compliances with usages requirement.
•Detect abnormality using five human senses.
•Improve maintenance skills.
•Provide technical support to Jishu Hozen activities.
•Restore machine condition.
•Identify design weaknesses.
PM Implementation
ANAND U 87
Role of Production Department
• Selection of critical locations in the m/c
• Machine mechanism training to the operators
• Development of PM plan • Day to day preventive maintenance
• Regular m/c inspection• Quick and correct information to the maint deptt
• Involvement of operator in repair activity
• Ideas to improve maint activities
PreventiveMaintenance
ANAND U 88
Role of MaintenanceDepartment
• Selection of critical locations in the m/c
• Machine mechanism training to the operators
• Development of PM plan• Support to Jishu Hozen – Red tag removal
• Scheduled preventive maintenance
• Spare parts management
• Breakdown analysis• Monitoring maint measures as MTBF, MTTR
PreventiveMaintenance
• Activities to prevent reoccurrence of problem
• Improvements in design weaknesses
ANAND U 89
ProductionDepartment
MaintenanceDepartment
Aim Should be Productivity Improvement
ANAND U 90
7.Early
Detectionof m/c
Abnormality
7.Early
Detectionof m/c
Abnormality
6.Minor
Repairs
6.Minor
Repairs
5.Proper
Operation
5.Proper
Operation
4.Tightening
4.Tightening
3.Inspection
3.Inspection
2. Lubrication
2. Lubrication
1. Cleaning
1. Cleaning
Job ofOperator
in Prev Maint
Job ofOperator
in Prev Maint