50593327 tpm basics and am step 1 to 5

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


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:


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



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



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


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


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


ANAND U 70

Quick Repair TPM Meetings Step System Step Audit Promote Success Stories


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


ANAND U 85


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

50593327 tpm basics and am step 1 to 5

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