1.tpm awareness information en
DESCRIPTION
TRANSCRIPT
1
Courtesy, in part, of Motorola SPS.Thank You!
Welcome To
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
2
Courtesy, in part, of Motorola SPS.Thank You!
About T.P.M.
After World War ll. Japanese industries determined that to complete successfully in the world market
they had to improve the quality of their products. to do so, they imported management and manufacturing
techniques from United States and adapted them to their circumstances. Subsequently, their products became
known throughout the world for their superior quality, focusing world attention on Japanese- style
management techniques.
TPM DEVELOPMENT PROGRAM
Implementing Total Productive Maintenance
Seiichi Nakajima.
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
3
Courtesy, in part, of Motorola SPS.Thank You!
WHAT IS T.P.M. ??
Definition of T.P.M :T.P.M. IS: A PRODUCTIVE MANUFACTURING SYSTEM with the TOTAL
Participation of: Managers, Supervisors, Engineers,
Technicians and Operators.
T.P.M. Includes the Following Benefits:
• Maximize Overall Equipment Effectiveness
• Establishment a Complete System of Maintenance for the Machine Entire
Life
• Create a Better Work Environment, Promoting the Participation for All
Employees
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
4
Courtesy, in part, of Motorola SPS.Thank You!
T.P.M. = Medical Science of Equipment
PRODUCTION Foton AUTOMATION B-820
VIDEO-AUTO DIE-BONDER MODEL 8030A
POWER
HEATER
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
5
Courtesy, in part, of Motorola SPS.Thank You!
The Main objective of TPM is :Zero Interruptions
Zero DefectsZero Accidents
Throughout total employees participation from Top Management to Operators,based in the following activities:
Autonomous Maintenance• Planned Maintenance
• Individual Improvement
• Quality Maintenance
• Early Equipment Management
• Education/Training (People Development)
• Safety
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
6
Courtesy, in part, of Motorola SPS.Thank You!
PILLARS OF TPM
AUTONOMOUS
MAINTENANCE
QUALITY
MAINTENANCE
PLANNED
MAINTENANCE
INDIVIDUAL
IMPROVEMENT
TRAINING
PEOPLEDEVELO
SAFETY
EHS
EARLY
EQUIP
MANAGEMENT
P
5S´s
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
7
Courtesy, in part, of Motorola SPS.Thank You!
T.P.M.Total Productive Manufacturing
People , Equipment and ProductImprovement by Working Together.
EXCELLENCE
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
8
Courtesy, in part, of Motorola SPS.Thank You!
PLANTOVERVIEW
PLANT
OVERVIEW
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
9
Courtesy, in part, of Motorola SPS.Thank You!
TPMSelf Assessment
PLANT
OVERVIEW
TPMSelf Assessment
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
10
Courtesy, in part, of Motorola SPS.Thank You!
TPM Self AssessmentBackground:
∆1991 First attempt to implement TPM.∆ TPM consultant provides training to selected Managers,Supervisors and Engineers.∆ One coordinator with experience in Process and Maintenanceis assigned to lead TPM.∆ Literature and materials, prepared and distributed.
Lack of support and involvement results on failing theimplementation.
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
11
Courtesy, in part, of Motorola SPS.Thank You!
TPM Self Assessment1996
∆ One Staff Mgr. is assigned to lead the TPM Implementationplant wide.
∆ A core team is formed on 2Q/96 with key people from differentdepartments to coordinate the implementation.∆ Model equipment is selected based on bottle neck operation.∆ Equipment conditions analysis performed.∆ Most of the teams cover the initial cleaning.∆ Activities are focused on six big losses detected and 5 S´s
implementation.
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
12
Courtesy, in part, of Motorola SPS.Thank You!
AsiaBenchmarking
PLANT
OVERVIEW
TPMSelf Assessment
AsiaBenchmarking
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
13
Courtesy, in part, of Motorola SPS.Thank You!
TPM BenchmarkingAsia Facilities
Facility 1 April1996
Facility 2Facility 3
Committee:
Objective:
Cayman Systems USA 513 777-3394©1998 Revision A 980810
May
June
4 Chosen Folks
Learn from Asia success experiences in TPMimplementation and come up with directions forPlant implementation.
TPM Awareness Information
14
Courtesy, in part, of Motorola SPS.Thank You!
Benchmarking Conclusions
Total management involvement.
T.P.M. Manager (dedicated).
A well defined implementation process.
Provide people with time to work on it. ( 4- 6 Hr./wk ).
Each staff has their own T.P.M. Promoter full time.
Focused in Consultant X model.
Focused in just one product line per area.
Budget assigned for consulting and external training.
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
15
Courtesy, in part, of Motorola SPS.Thank You!
TPMPLANT
OVERVIEW
TPMSelf Assessment
AsiaBenchmarking
TPMImplementation
Cayman Systems USA 513 777-3394©1998 Revision A 980810
Implementation
TPM Awareness Information
16
Courtesy, in part, of Motorola SPS.Thank You!
IMPLEMENTATION/CONSULTANT
* Q3 1996, Consultant X is selected to be Consultant.
* Training of Managers, Team leaders and Team members
* Master Plan Defined
* TPM. implementation initiated according to Consultant X recommendations
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
17
Courtesy, in part, of Motorola SPS.Thank You!
T.P.M. POLICY# ESTABLISH AN INTEGRATED STRUCTURE TO PROMOTE T.P.M.
AS A COMPANY CULTURE.
# MAXIMIZE OVERALL EQUIPMENT EFFECTIVENESS
# TOTAL EMPLOYEE INVOLVEMENT.
# CULTIVATE EQUIPMENT & PROCESS RELATED EXPERTISE THROUGHOUTSHOP FLOOR. ( Autonomous Maintenance, Planned Maintenance etc..)
# ESTABLISH A RELIABILITY AND MAINTAINABILITY SYSTEM TO MAXIMIZEEQUIPMENT LIFE TIME. (Planned Maintenance Autonomous Maintenance,Individual Improvement, Early Equipment Management.)
# ALL EMPLOYEES MUST PARTICIPATE IN T.P.M TRAINING PROGRAM.
# ALL AREAS MUST FOLLOW T.P.M. ESTABLISHED GUIDE LINES.
# DEPARTMENT HEAD IS RESPONSIBLE TO ACCOMPLISH AND SUPPORTT.P.M. GOALS.
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
18
Courtesy, in part, of Motorola SPS.Thank You!
T.P.M. PLANT WIDE STRUCTURE
TPM
T.P.M. Office ResponsiblePlant Manager
5 ´sAutonomousMaintenance
PlannedMaintenance
IndividualImprovement
QualityMaintenance
EarlyEquipment
ManagementSafety
TrainingPeople
Development
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
19
Courtesy, in part, of Motorola SPS.Thank You!
PROMOTION STRUCTURE(OVERLAPPING SMALL GROUPS)
PLANTMANAGER
STAFF MANAGERS
OPERATIONS
TPM PILLARS& PROMOTION
OFFICE
TPMPROMOTERS
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
DEPARTMENTMANAGERS
DEPARTMENTSUPERVISORS
TPM TEAM
20
Courtesy, in part, of Motorola SPS.Thank You!
VISION STATEMENT:TPM
PLANT WIDE
IMPLEMENTATION
Q1 2000
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
21
Courtesy, in part, of Motorola SPS.Thank You!
T.P.M. IMPLEMENTATION ACTIVITIES
MANAGER TEAMS
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
22
Courtesy, in part, of Motorola SPS.Thank You!
PREPARATION / PLANNING STAGE
# DEFINE PILOT LINES
# AMOUNT OF MACHINES INCLUDED PER LINE
# DEFINE CORE TEAM MEMBERS OF EACH LINE
# SELECT TEAM MEMBERS PER MACHINE
# START ACTIVITIES IN PILOT MACHINES (bottle neck.)
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
B-820
B-609
V-701
23
Courtesy, in part, of Motorola SPS.Thank You!
Line and Machine Selection
B-820
Machine 1 Machine 2N-661
POWER
HEATER
Machine 3 Machine 4B-609
V-701
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
START
TA
TPM Implementation PlanACTIVITIES
DEFINE STRATEGIES
1996 1997 1998 1999 2000Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2
PREPARATION
STAGE
MASTER PLANORGANIZATION
INTRODUCTION TRAININGPUBLICITY
1TPM
2 3
IMPLEMENTA
MODEL MACHINESMachine 1Machine 2Machine 3Machine 4
EXTENDIMPLEMENTATION
SIMILARPRODUCTION LINES
KICK
OFF
AUTONOMOUS MAINTENANCE&
REDUCE 6 BIG LOSSESEXTEND SIMILAR MACHINES
30%to
50%
TION
RGET
COMPLETEIMPLEMENTATIONDEFINED AREAS
100%
TPM 90 Days Explosion PlanOctober November December
ww40 ww41 ww42 ww43 ww44 ww45 ww46 ww47 ww48 ww49 ww50 ww51 ww52Machine 1
PILOT TEAM Step 3Planned maintenance
6 big lossesIndividual Improvement
Start
StartStart
Start10 Extension teams19 Extension teams
step 1-2Start step 1
4 mc7 mc
3 mc6 mc
3 mc6 mc
Machine 2PILOT TEAM Step 2-3
Planned maintenanceStart
Start6 big losses
Individual ImprovementStep 1 Step 2
Step 111 Extension teams step 1-2 B-613 3 mc 2 mc 2 mc B-601 L-604
Machine 3PILOT TEAM Step 2-3
Planned maintenance6 big losses
Individual ImprovementStart
Start
Start
Start
6 Extension teams2 Extension teams
Machine 4PILOT TEAM
step 1-2Start step 1
Step 1-2
Start
Start
2 mc 4 mc
Planned maintenance6 big losses
Individual ImprovementStart
Start
Start4 extension teams Start step 1 a-820 a-821 J-701 J-601
PILLARS IMPLEMENTATION MODELGANTT
TPM Activity Board Extension TeamsServer Data collection M1 M2 M3 M4
GM AuditTeam presentationsTPM Office AuditConsultant visitTPM MeetingLocal BOOT CAMPTPM MCOE MEETING, JAPANPillars meeting
M
CO
DENIAL
M
MEN
T
T
I
RESISTANCE
EXPLORATION
26
Courtesy, in part, of Motorola SPS.Thank You!
T.P.M. TRANSITION CURVEPOLICIES DEVELOPMENTT.P.M. PROMOTION OFFICE START
MANAGEMENT MACHINESFOCUS IN FEW EQUIPMENT
T.P.M. PROMOTION DELEGATIONINCLUDE T.P.M. IN PERFORMANCEMANAGEMENT PLAN.INCLUDE T.P.M. IN JOB
KICK OFF
FOCUS TRAININGSUCCESS STORIES5 S´s
CONSULTANTIN
DESCRIPTION.ACCELERATEDDEPLOYMENT.
CONSULTANTOUT
DEVELOP DATA COLLECTION SYSTEMATTENTION TO FOCUS TEAMSTRAINING DEPLOYMENTIMPLEMENTATION PLANRESOURCE IMPLEMENTATION
GOALS SETTING FORALL ORGANIZATION.
LOOK FOR ADDITIONAL WAYSTO DEPLOY T.P.M.
FINISH CONFLICT WITH THE CULTUREORGANIZATION ALIGNMENTREWARD SYSTEMCONTROL CHAOS
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
2X
27
Courtesy, in part, of Motorola SPS.Thank You!
KEY GOALS
1.- TOTAL EQUIPMENT EFFECTIVENESSA) Equipment BreakdownB) M.T.B.A.C) M.T.B.F.
2.- REJECT CAUSED BY LINE EQUIPMENT
3.- LINE REJECT RATE
4.- CYCLE TIME
5.- FATAL ERROR AT CUSTOMER
6.- ON TIME DELIVERED
7.- MANUFACTURING COST
%HOURS/MONTHMINUTESHOURS
PPM
%
DAYS
# OF
%
USD
851/101x10x1x2x
1/5
1/5
0.8X
0
98
20% LESS
8.- LABOR PRODUCTIVITY
Cayman Systems USA 513 777-3394©1998 Revision A 980810
K.UNITS /# OF D/L
TPM Awareness Information
28
Courtesy, in part, of Motorola SPS.Thank You!
AUTONOMOUS MAINTENANCE.
MANUFACTURING SPECIALIST
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
29
Courtesy, in part, of Motorola SPS.Thank You!
AUTONOMOUS MAINTENANCE IS:
Maintenance performed by equipment operators.
THE FIRST 3 STEPS OFAUTONOMOUS MAINTENANCE.
STEP # 1 INITIAL CLEANING.
STEP # 2 COUNTERMEASURES FOR THE CAUSESOF FORCED DETERIORATION AND IMPROVINGHARD-TO-ACCESS AREAS.
STEP # 3 MAKING A TENTATIVE CLEANING/LUBRICATION STANDARD.
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
3
7
2
30
Courtesy, in part, of Motorola SPS.Thank You!
AUTONOMOUSMAINTENANCE
5
4
Selection
Formats:Daily Cleaning &Initial InspectionHot Spots, CAP-DO5W´s Develop One
Major Problems Point lesson
6
Put F Tags
Step # 1
Initial Cleaning
StandardizationCleaning /Lubrication
Initial Cleaning(Inspection)
Training inOne Point Lesson
Photos BeforePhotos After
1
8
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
3 7
31
Courtesy, in part, of Motorola SPS.
AUTONOMOUSMAINTENANCE
5
Thank You!
4
Put “F” Tags
Failures AnalysisWhy´s Analysis
Actions inSources ofContamination &Hard access areas
Step # 2
6
Find & ListAreas of HardAccess
Sources ofContamination &
Hard Access Areas
Modify Covers ForEasy Visualization
& QuickDisassemble
Find & ListSources ofContamination Remove “F” Tags
Cayman Systems USA 513 777-3394©1998 Revision A 980810
2 Initial InspectionFinal Inspection
(Audit)
1
TPM Awareness Information
8
46
373
32
Courtesy, in part, of Motorola SPS.
AUTONOMOUSMAINTENANCE
5
Thank You!
Verifyactual time
Improve time ofexecution
Detailactivities
Vs estimated
Put “F” Tags(Establish time& frequency)
Step # 3TentativeStandards
Remove“F” Tags
Cleaning / Lubricationimplementation Apply activities to
similar machines
22
Develop tentativestandards 8
1
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
443427
12
33
Courtesy, in part, of Motorola SPS.Thank You!
TPM Teams Status
October 1997
•Number of Hot Spots detected:•Number of Hot Spots solved:•One Point Lesson developed:•One Point Lesson Taught:•Number of teams on TPM:•Teams on step 3:•Teams on step 2:•Teams on step 1:
284126
24
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
34
Courtesy, in part, of Motorola SPS.Thank You!
PLANT
OVERVIEW
TPMSelf Assessment
AsiaBenchmarking
TPMImplementation
Expansion Plan
Cayman Systems USA 513 777-3394©1998 Revision A 980810
Expansion Plan
TPM Awareness Information
1998
35
Courtesy, in part, of Motorola SPS.Thank You!
T.P.M. DEPLOYMENT
LINE
FLOW
CURRENT EQUIPMENT IN T.P.M.
SAME KIND OF EQUIPMENT
1999/2000 EXPANSION
1997
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
Line
36
Courtesy, in part, of Motorola SPS.Thank You!
PROJECTED PROGRESS IN TEAMS Q-1’ 98
A.M. STEP # 1 A.M. STEP # 2 A.M. STEP # 3
Wafer ProcessLine 1
Line 2
Line 3
Line 4
Cayman Systems USA 513 777-3394©1998 Revision A 980810
11
03
03
04
TPM Awareness Information
16
11
08
01
03
01
01
01
37
Courtesy, in part, of Motorola SPS.Thank You!
T.P.M. FOLLOW-UP
TEAMSPRESENTATION
TEAMSAUDITS
TEAMSMEETING
Consultant X MANAGERSVISITS PRESENTATION
6 TEAMS
PER
MONTH
6 TEAMS
PER
MONTH
WEEKLY TWO DAY
EVERY
TWO
MONTHLY
MEETING
MONTHS
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
38
Courtesy, in part, of Motorola SPS.Thank You!
PLANT
OVERVIEW
TPMSelf Assessment
AsiaBenchmarking
TPMImplementation
Expansion Plan
Pilot TeamCase Study
Cayman Systems USA 513 777-3394©1998 Revision A 980810
Pilot TeamCase Study
TPM Awareness Information
39
Courtesy, in part, of Motorola SPS.Thank You!
PILOT MACHINE
N-62361
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
40
Courtesy, in part, of Motorola SPS.Thank You!
Defectives30
25
20
23
20
25
22
1820
21
1719
23
15
10
55
78
65
9
6
3 4 3 32
4
6
8
65
4
76
0N-662361 N-61162 N-634766
JAN 96JUN
FEBJUL
MARAUG
APRSEP
MAYOCT 96
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
%T.C.
ENE./96MAR MAY JUL
OCT./96ABR
%T.C.
ABR
AGO
ENE./96AGOMAR MAY SEPFEB JUN JUL
SEPFEB JUN
OCT./96
%T.C.
FEB JUN AGOMAROCT./96ENE./96
MAYABR JUL SEP
41
Courtesy, in part, of Motorola SPS.Thank You!
DOWN TIME25%
23% 23%
20% 20% 20%
N-66236115%
10%
17%18%
12%
15%
18% 18%
5%
0%
25%
20%
N-66324215%
10%
5%
12%11%
10%11%
8%9%
7%6%
8%10%
0%
25,00%
20,00%
15,00%
N-649666 10,00%
5,00%7,50% 8%
4%
7%9%
5%3%
5% 6%8%
0,00%
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
42
Courtesy, in part, of Motorola SPS.Thank You!
CLEANING IS INSPECTION....
5’S
AUTONOMOUS
MAINTENANCE
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
43
Courtesy, in part, of Motorola SPS.Thank You!
INSPECTION IS DETECTION.
CRASH
Broken Part
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
44
Courtesy, in part, of Motorola SPS.Thank You!
PRESSURECORRECT
INCORRECT
TO MUCHPRESSURE
CORRECT
GAUGE
ALIGNMENT
INCORRECT
NO
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
45
Courtesy, in part, of Motorola SPS.Thank You!
CORRECT CENTERING
INCORRECT
Dummy Part
CORRECT
SYMMETRY
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
INCORRECT
BENT
46
Courtesy, in part, of Motorola SPS.Thank You!
CONTACT
CORRECTINCORRECT
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
47
Courtesy, in part, of Motorola SPS.Thank You!
TO STANDARDIZE AND
PREVENT RECURRENCE
One Point Lesson
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
48
Courtesy, in part, of Motorola SPS.Thank You!
MACHINEPERFORMANCE
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
Abr MayOct-96Sep-96 Dec-96Jan-97
AgoMarFeb Jun Jul
%D.T.
Nov-96Apr May
Dec-96 Jan-97Feb
Oct-96Mar Aug SepJun Jul
Sep
49
Courtesy, in part, of Motorola SPS.Thank You!
Defectives25
20
15
23
18
“ZERO”
1010
6
Defectives
5 3
12
0 0 0 0 00
25%
20%18%
DOWN TIME
20%
P.C. BOARDDAMAGED
15% 15%
12%10%
5%
9%8%
7%5%
6%4%
3% 3%0%
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
3
50
Courtesy, in part, of Motorola SPS.Thank You!
WHAT IS NEXT?
6 Big
LINK Losses
44
AutonomousMaintenance
Planned
Maintenance
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information
51
Courtesy, in part, of Motorola SPS.Thank You!
Cayman Systems USA 513 777-3394©1998 Revision A 980810 TPM Awareness Information