TPMTPM
1. TPM – basic idea
2. Organisational structure of the TPM project
3. Presentation of the project and 6 sub-projects
4. TPM in Kolektor – results and goals
5. Questions and suggestions
DEVELOPMENT OF MAINTENANCEDEVELOPMENT OF MAINTENANCE
� BREAKDOWN MAINTENANCE
� PREVENTIVE MAINTENANCE (PM - 1951)
� CORRECTIVE MAINTENANCE (CM – 1957)
� MAINTENANCE PREVENTION (MP – 1960)
� PRODUCTIVE MAINTENANCE (PM + CM + MP)
� TOTAL PRODUCTIVE MAINTENANCE (TPM® – 1971)
Total in TPM means :
total effectiveness
total maintenance and
total paricipation of all employees
DEFINITION AND DISTINCTIVE DEFINITION AND DISTINCTIVE FEATURES OF TPMFEATURES OF TPM
� TPM aims to maximize equipment effectiveness
� TPM establishes a thorough system of PM for the equipments entire life span
� TPM is implemented by various departments(engineering, operations, maintenance)
� TPM involves every single employee, from top management to workers on the floor
� TPM is based on promotion of PM through
motivation management: autonomous small groups activities (TED in Kolektor)
OVERALL EQUIPMENT
EFFECTIVENESS
5S
AUTONOMOUS MAINTENANCE
QUICK CHANGEOVER-
SMED
IMPROVEMENT SUGGESTIONS
PREVENTIVE MAINTENACE
VlekIgor Bonč inaDejan Čadež
Divizija AMartin Kolenc
Uroš Felc
Stojan PetričPredsednik družbe
Radovan BolkoPodpredsednik družbe
Sebastjan FranziniVodja projekta
5SVodja: Andrej ViherDiv. A: Simon PavšičDiv. B: Andrej ViherDiv. C: Zdenko OgričDiv. D: Zdravko PelhanVlek: Dejan ČadežOrod..: Sebastjan FranziniASCOM: Nina Vest (nam.)Vzdrževanje: Aleksander Rutar
SAMOVZDRŽEVANJEVodja: Janez GostišaDiv. A: Simon PavšičDiv. B: Jure Benč ina (nam.)Div. C: Zdenko OgričDiv. D: Zdravko PelhanVlek: Dejan ČadežOrod..: Sebastjan FranziniASCOM: Bojan Hvala
MALE IZBOLJŠAVEVodja: Sebastjan FranziniDiv. A: Ivan KofolDiv. B: Veronika HitiDiv. C: Dejan Velikanje (nam.)Div. D: Boris JezeršekVlek: Igor BončinaOrod..: Sebastjan FranziniASCOM: Tatjana Carl
HITRA MENJAVA ORODIJVodja: Andrej BrložnikDiv. A: Uroš FelcDiv. B: Andrej BrložnikDiv. C: Janez Gostiša (nam.)Div. D: Zdravko PelhanVlek: Dejan ČadežOrod..: Sebastjan FranziniASCOM: Boris Carli
PREVENTIVNOVZDRŽEVANJEVodja: Ivo LogarDiv. A: D. Krapež, E. NamarDiv. B: I. Gnezda, M. MiheljDiv. C: P. Poljanec, B. FilipičDiv. D: P. Poljanec, B. FilipičVlek: M. Bratuž, T. ŠtravsOrod..: P. Poljanec, B. FilipičASCOM: M. Bratuž, T. Štravs
Divizija BSilvo Jesenko
Andrej Brložnik
Divizija CStanislav JerebJanez Gostiša
Divizija DValter LebanAleš Gostiša
OrodjarnaMiloš Kermavnar
Sebastjan Franzini
VzdrževanjeMarjan BrusIvo Logar
ASCOMBojan SeverNina Vest
ORGANIZACIJSKA STRUKTURA PROJEKTA TPM
UČINKOVITOST OPREMEVodja: Robert KosDiv. A: Robert KosDiv. B: Andrej Brložnik (nam.)Div. C: Dejan VelikanjeDiv. D: Aleš GostišaVlek: Igor BončinaOrod..: Sebastjan FranziniASCOM: Dimitrij Bevk
OVERALL EQUIPMENT EFFECTIVENESS
OEE = Availability x Performance x Qualityrate rate
BreakdownsSetupAdjustment
IdlingMinor stoppagesReduced speed
Defects and reworkStartup loss
Two types of equipment effectiveness in Kolektor:
OEE – calculated with all stillstandsPEE – exclude stillstands caused by poor
organization
OVERALL EQUIPMENT EFFECTIVENESSOVERALL EQUIPMENT EFFECTIVENESSOVERALL EQUIPMENT EFFECTIVENESSOVERALL EQUIPMENT EFFECTIVENESS
OVERALL EQUIPMENT EFFECTIVENESS
In all calculations we consider all stilstands, regardless of the reason:
Availability:
Net available time = Working days x Shifts x Planned no. of hrs/shift + exceptions
time available Net
time sstillstand All- time available Net=R
Performance effectiveness: time stilstands All- time available Net
run parts Totalx time cycle Ideal=Z
Quality rate: run parts Total
run parts Good=K
Overall equipment effectiveness:
SU = R x Z x KSU = R x Z x KSU = R x Z x KSU = R x Z x K
STILLSTANDS – TYPES AND DIVISION
Stillstands caused by equipmentStillstands caused by equipmentStillstands caused by equipmentStillstands caused by equipment
03 Tool missing
10 Machine breakdown
11 Tool breakdown
12 Set-up of machine/tool Bigger set-ups, change of tool, change of programme…
15 In-process set-up Shorter stillstands due to adjustments, …
23 Working place not in order Zastoji zaradi nepopolne urejenosti delovnega mesta (npr. – stroj naj bi delal avtomatsko, pa še ni avtomatiziran; ni zabojev; ni palet; ni VF generatorja…)
29 Autonomous maintenance Cleaning, lubricating, tightening, checking…
30 Technological problems
91 Poor quality The stillstand must have an according note of poor Q
Other stillstands Other stillstands Other stillstands Other stillstands (independent on equipment) – organisational stillstands 01 No work No work because there are no job-orders for the machine
02 No raw material
04 No energy
05 No set-up man
14 No material – semi-product
98 No worker
PSU = PR x Z x KPSU = PR x Z x KPSU = PR x Z x KPSU = PR x Z x K
PRODUCTION EQUIPMENT EFFECTIVENESS
When calculating production availability we consider only the stillstands caused by equipment. It tells us, how much of the planned time, the machine is capable of operating and there are no stillstands caused by poor organization.
Production availability: time sstillstand onalOrganisati - time available Net
time sstillstand All- time available Net=PR
Production equipment effectiveness: • Theoretical equipment effectiveness is calculated regarding to maximum available time
(callendar days x 24 hrs).
OEE (SU) AND PEE (PSU) IN KOLEKTOR OEE (SU) AND PEE (PSU) IN KOLEKTOR JANUARY JANUARY –– MARCH 2003MARCH 2003
Exploatation rate (I)
Production availability
(PR)Availability
(R)Performance
(Z)Quality
(K)
Overall equipment
effectiveness (SU=R*Z*K)
Production equipment
effectiveness (PSU=PR*Z*K)
Theoretical equipment
effectiveness (SUt)
DIVIZIJA A 0,885 0,890 0,875 0,871 0,996 0,759 0,771 0,604DIVIZIJA B 0,717 0,862 0,706 0,854 0,997 0,601 0,734 0,411DIVIZIJA C 0,676 0,885 0,649 0,834 0,997 0,539 0,736 0,301DIVIZIJA D 0,702 0,848 0,689 0,810 0,998 0,557 0,686 0,355PROKOL 0,818 0,868 0,801 0,914 0,998 0,730 0,791 0,523VLEK 0,736 0,789 0,722 0,747 1,000 0,540 0,589 0,288
KOLEKTOR 0,745 0,870 0,730 0,844 0,996 0,614 0,732 0,402
Overall equipment effectiveness
0,000
0,100
0,200
0,300
0,400
0,500
0,600
0,700
0,800
DIVIZIJA A -skupaj
DIVIZIJA B -skupaj
DIVIZIJA C -skupaj
DIVIZIJA D -skupaj
PROKOL -skupaj
VLEK - skupaj KOLEKTOR -skupaj
II kvartal 2002
III. Kvartal 2002
IV. Kvartal 2002
I. Kvartal 2003
Production equipment effectiveness
0,000
0,100
0,200
0,300
0,400
0,500
0,600
0,700
0,800
0,900
DIVIZIJA A -skupaj
DIVIZIJA B -skupaj
DIVIZIJA C -skupaj
DIVIZIJA D -skupaj
PROKOL - skupaj VLEK - skupaj KOLEKTOR -skupaj
II kvartal 2002
III. Kvartal 2002
IV. Kvartal 2002
I. Kvartal 2003
AUTONOMOUS MAINTENANCEAUTONOMOUS MAINTENANCE
� Autonomous maintenance refers to activities designed to involve operators in maintaining their own equipment, independent of the maintenance department
� It’s based on education and training of the operators
AUTONOMOUS MAINTENANCEAUTONOMOUS MAINTENANCE
� Daily checks
� Lubricating
� Parts replacement
� Simple repairs
� Precision checks
� Abnormality detection
We’ll clean every nook and cranny
Anything we can fix right away, we
will
Anything wrong here?
STANDARD SAMOVZDRŽEVANJA Stroj: STROJ RAZŽAGOVALNI AVT. TIP:RŽA 52/L-99 TED: Obrat: DIVIZIJA A
Št. stroja: 40495 Št. OS: 11621 Pogostost
Shema: Št. Opis Kriterij Metoda
Orodje/ mazivo I D T M
Odgovorni
1
Čiščenje stroja Površine stroja čiste Ročno Krpa, čistilo, metla, omelo
X Urejevalec
2 Kontrola nastavitve vpenjanja Pravilna nastavitev Test X
Urejevalec
3 Sesanje špen iz stroja Čist stroj Ročno Sesalec za špene
X Urejevalec
4 Mazanje ležajev ojnice Ležaji namazani Ročno Ročna mazalka/ Mast 90
X Urejevalec
5 Kontrola ožičenja
El. kabli ne smejo biti poškodovani, obrabljeni ali dotrajani, ne smejo prosto viseti po stroju
Vizualno X Urejevalec
6 Kontrola tesnjenja pnevmatike Brez puščanja Vizualno Slušno
X Urejevalec
7 Kontrola delovanja varnostnih sistemov (stikal)
Stroj ne deluje če: - zaščitno stikalo ni aktivirano
- je nujni stop vklopljen
Aktiviranje ali izklop varnostnih sistemov
X Urejevalec
8 Kontrola nastavitve optičnih in induktivnih senzorjev
Senzorji brez fizičnega kontakta
Vizualno X Urejevalec
Opombe: V primeru ugotovitve odstopanja, ki ga sami ne morete odpraviti, obvestite službo vzdrževanja.
Izdano dne: Odobril:
4
7
6
2
AUTONOMOUS MAINTENANCE IN AUTONOMOUS MAINTENANCE IN KOLEKTORKOLEKTOR
Development of Autonomous maintenance plans:
Number of machines
Standards made
Standards to be made
Conclusion plan
DIVIZIJA B 297 277 20 15.04.03DIVIZIJA A 354 41 313 15.06.03PROKOL 60 0 60 30.06.03DIVIZIJA C 215 40 175 31.07.03ORODJARNA 79 19 60 31.08.03VLEK 25 1 24 15.09.03ASCOM 253 6 247 31.11.03DIVIZIJA D 21 21 0 ConcludedSKUPAJ 1304 405 899 31.12.03
LEKCIJA Z ENO TEMO
Številka PREŠANJE 02
Tem
a
KONTROLA NASTAVITVE FOTOCELIC Datum izdelave
27.02.2002
Vodja oddelka Izdelal
Kla
sifi
kaci
ja
Osnovno Področje Problematično znanje izboljšav področje L. Gnezda,
R. Blaznik D. Brložnik
Datum
Predstavil
Slušatelji
Obr./1-1/386
Za kontrolo (nastavitev) fotocelic pritisni
tipko . Utripati prične rdeča lučka.
Na nasprotni strani mora žarek padati v
sredino belega kroga s križcem ali satjem. Kontrolo ponoviti na zgornji in spodnji strani. V primeru neustrezne nastavitve pravilno lego fotocelic nastaviti z ustreznim premikom nosilca fotocelic.
Single point lessons are a useful instrument for simple explanation and presentationof individual jobs, measures, improvements ... Especially in the field of autonomous maintenance
How How to to measure the effectiveness measure the effectiveness of TPM of TPM implementationimplementation??
� OEE and PEE� Time spent on corrective maintenance� Time spent on preventive maintenance� Total maintenance time� MTBF (mean time between failures)� MTTR (mean time to repair)� Stillstands time� Stillstands structure� Scrap� Number of improvement suggestions
Workplace before TPM
Workplace after TPM