tpmoverview_382

TPM

T- Total

P- Productive

M- Maintenance ( Or Management)

What is TPM.

TPM is a management strategy to get superior business results.

TPM improves Capability of all employees. TPM develops Team work to achieve better results and

involves every one. TPM develops an edge over competition. TPM brings about a step improvement in all business

results. TPM, once implemented does not need any other

strategy.

TPM is Not….

Just a set of activities.Just a new method of Maintenance.Just to bring about discipline.Just a right thing to do.Having any conflict with Six Sigma,TQM, QC or

Kaizen.Something which is delegated down wards.

Vision

Power of Zero

Power of 100%

Vision

Power of zero defects

Power of 100% Employee Involvement

Power of Zero defects

Just Imagine that if 1% of all the flights crashed.

Just Imagine that if 1% of all the heart surgeries failed.

Just Imagine that if 1% of the buildings collapsed soon after construction.

Power of 100% Employee Involvement

Days Of “Boss” doing “thinking” and all others “working” as per his/her instructions are gone.

People are Enthusiastic to take part and have sense of achievement.

Decision can be taken by the person at the point of action and with relevant information.

There is huge amount of Energy in 100% Employee Involvement.( TEI)

Origin of TPM

Tremendous Global Competition Image Of Japanese Products in Fifties and Sixties Dr. Deming’s teachings implemented widely in Japan in

1960s. 5-S and Quality Circles and Kaizen achieved some Success Evolution Of TPM started in Japan in seventies by Japan

Institute of Plant Maintenance ( JIPM- Tokyo). Today thousands of companies all over the world are doing

TPM. In India we have more than 100 companies doing TPM right now.

What is 5-S

Seiri - Discard unwanted items. Seiton - Organize for no search time. Seiso -Clean for checking defects. Seiketsu -Maintain equipment and work place for efficient

functioning. Shitsuke -Disciplined( New culture) Behavior

Some Principles Of TPM

Machine condition, Settings and correct operation are Key to Good Quality Product.

“I Run it and you fix it “ Concept has serious Limitations. If the Hen is Healthy it will give healthy Eggs. “Begin with the End in Mind” – Stephen Covey. Operator needs to Have Proper Attitude and skills to get

quality Product.

Some Principles of TPM

Zero defects or Zero loss state can be achieved only if we prioritize and go step by step.

Leadership has to play a key role in implementing TPM and can not be delegated to technicians.

TPM is Top Down as well as bottom up. It is not a project, it is a continuous improvement

journey. It is not one man’s project. It is a collective effort.

Benefits by implementing TPM

First Of all – The Big Culture Change. All the Measures-PQCDSM will improve in a big way. Reliability improves and creates more Capacity in the

existing plant. The Skills of Employees go Higher and Higher and so

you are ready for any new Challenge. Zero Break downs and Zero Minor Stops. All round improvement in Plants, Processes, systems

and People.

Impact on Bottom Line

P- Productivity will go higher 25%- 50% Q- Quality Defects will be minimum; < 500 PPM C- Cost of Mfg will be Lower - 10%-25% D- Delivery will get Better Reliability- 100% S- Safety incidents and accidents will be Zero M- Morale of people will go high tremendously

Benefits on People Front.

A Highly Disciplined work Place

Highly Skilled Employees

High Respect for individual Capabilities

Take On Bigger Business Challenges

Very Flexible and Conscious work force

Pillar Structure Of TPM

Autonomous MaintenanceProgressive MaintenanceFocused ImprovementEducation and TrainingQuality MaintenanceEarly Equipment ManagementAdministrative SupportSafety, Health and Environment

What does the structure Mean

These are similar to Pillars of a building. These are conceptual bodies of knowledge and not

departments or water tight compartments. These are faculties which help each other to achieve

the final Objective of Zero loss/defect. There is a lot of give and take from each Pillar. Ultimate aim is to make employees more capable and

develop a culture so that they can achieve the objective.

Autonomous Maintenance

What It does.

- Creates Self Sufficient Operators with tremendous Ownership.

- Clean and Best quality Equipment to Produce Best quality Products.

What will you get.

- Zero Breakdowns and Minor Stoppages.

- Higher Capacity and Increased Equipment Life.

- Better returns from the same machines.

Progressive Maintenance

What it does.-Training and Partnership to equipment operators.

- Systematic and Cost Effective Maintenance System.

1. Time Based Maintenance System 2. Corrective Maintenance.

3. Predictive(Condition Based) Maintenance 4. Maintenance Prevention.

What will you get.- Increase the life span of the Equipment and critical components.

- Zero Breakdowns.- Reduced Maintenance cost.- Design input to get Better Equipment.

Focused Improvement

What it does.-Systematically identifies and Eliminates all losses.- Eliminates all Chronic Problems in the Process.- Develops good Problem solving skills in People.- Encourages “Kaizen” in the Plant.- Develops Team work and sense of achievement.

What will you get.- Savings in cost of Mfg. By elimination of losses.- Better Quality by elimination of Chronic losses.- Develops Great Satisfaction in Employees.

Education & Training

What it does.- Develops Skills in Operation and Maintenance.- Develops Self Sufficient(Autonomous) Operators.- Develops Problem solving Skills.- Develops Teamwork and Organizational Skills.

What will you get.- Highly skilled Employees.- Capability for facing Future business Challenges.- Employees will be able to see direct link between

their Efforts and business growth.

Quality Maintenance

What it does.- Identifies Direct link between the Process Inputs(4M+E) and Product Quality.- Identifies operator skill-gaps to get best quality.- Comply Statutory & Mandatory requirements.

What will you get.- Very highly quality conscious & skilled operators.- Best competitive quality and elimination of consumer complaints.

Early Equipment Management

What it does.- Takes all inputs from the Plant Data System and incorporates into new equipment design.- Systematic approach towards MP Design.- Takes all inputs from operators for Maintainability

and Operability. What will you get.

- New Equipment with all inputs incorporated.- Tremendous advantages in terms of life cycle cost, operability and maintainability.

Administration & Support

What it does.- Highly responsive & Productive Support System.- Elimination of Losses in the Administrative Dept.- Better Productivity in admin. & Support Dept.

What will you get.- Better Organization image and Product Franchise.- Savings by Elimination of Losses in Admin.Dept.- Involvement Of Admin.Staff in the whole Plant effort of TPM.

Safety,Health and Environment

What it does.- As the name indicates improves safety of the People,Plant and equipment.- takes care of Environmental impacts on the Health and Hygiene of Employees.

What will you get.- Enhances company’s image by good records.- Better Employee satisfaction in the long run.- Saves company huge losses and Penalties.

How does the integration help

Autonomous Maintenance can not sustain on its own. Though Autonomous Maintenance is the Mother pillar. It needs a lot of support from others. Maintenance training( Self managed) Loss analysis and elimination. Quality Maintenance support. Education and Training Leadership support.

Six big losses

Breakdown losses. Set-up and adjustment losses.Minor stoppage losses.Speed losses.Quality defect and rework losses.Yield losses.

Calculation of OEE.

Availability= (Loading Time- Down time)/ Loading time. Operation time- down time losses= Loading time. Loading time- speed losses = Net operation time

Performance rate= (Optimal cycle time x output)/ operation time.

Quality Rate= (Input- Reject) / Input

Overall Equipment Efficiency= Availability x performance rate x Quality Rate.

Losses in Assembly lines.

We just saw the six big losses.These are contributing to the Overall Equipment

Efficiency in an Engineering industry.However for an assembly line we need to look at 16

major losses.The reason being there are equipment and there

are people who also contribute to losses.

Seven Major losses which can impede OEE

Failure losses.Setting up and adjustment losses.Cutting blade losses.Start up losses.Minor stoppage and idling losses.Speed losses.Defect or rework losses.

Losses that can impede machine loading time

Shut down Loss

Five major losses that can impede human work efficiency

Management losses.Motion losses.Arrangement losses.Losses due to lack of automation.Monitoring and adjustment losses.

Three major losses that can impede effectiveness of resources.

Yield losses.Energy losses.Die, Jig and fixture losses.

Business Measures

P- Productivity, Production Volume or Process Reliability.

Q- Quality- expressed in PPM C- Cost of Mfg. D- Delivery-Reliability of delivery. S- Safety incidents and accidents. M- Morale of people.

Internal measures

What are internal measures. Measures to track at tactical level. Measures to be tracked by teams. They are normally contributing to business measures.

Some internal measures. No. of Breakdowns. Duration of breakdowns. Minor stoppages. MTBF. MTTR. Quality defects. Scrap or wastages.

Self Managed( Autonomous) Maintenance.

Cleaning, Inspection and lubrication. Cleaning is to find defects. Have a critical eye and find all defects. Prioritize the defects and start eliminating those. Identify chronic problems in your area and analyze them. Learn your equipment fully including power transmission,

settings, centerlines, quality standards etc. Learn daily maintenance activities and do them. Reduce all minor stoppages to zero..

Step 1 : Initial Cleaning

Step 1 Step 2 Step 3Initial cleaning Address sources

of problemsSet cleaning, inspection,and lubrication standards

Restoration Improvement Improvement

al

Cleaning, Inspection, lubrication target time

Cleaning, Inspectiontarget time

conta

OVERALL OBJECTIVERestore equipment/process to ideal conditionBegin developing people’s skill to identify abnormalconditions

Step 2 : Address Sources of Problems

OVERALL OBJECTIVES:• Address remaining abnormalities & problems• Make the equipment conditions established easier to maintain • Develop people’s ability to identify the root cause of problems and make

improvements • Further eliminate losses

Step 1 Step 2 Step 3Initial cleaning Address sources

of problemsSet cleaning, inspection,and lubrication standards

Restoration Improvement Improvement

al

Cleaning, Inspection, lubrication target time

Cleaning, Inspectiontarget time

conta

Step 3 : Set Cleaning, Inspection and Lubrication Standards

OVERALL OBJECTIVES• Address the problems and abnormalities identified in the Lubrication

System• People have acquired the hands-on skills to properly maintain these

conditions • Finalize the standards that will maintain equipment conditions and

results

Step 1 Step 2 Step 3Initial cleaning Address sources

of problemsSet cleaning, inspection,and lubrication standards

Restoration Improvement Improvement

al

Cleaning, Inspection, lubrication target time

Cleaning, Inspectiontarget time

conta

7 Steps of Autonomous Maintenance

Phase I Phase II Phase III Phase IV

STEP 1

STEP 2

STEP 3

STEP 4

STEP 5

STEP 6

STEP 7

. Restore Equipment toBasic Conditions

CleaningInspectionLubrication

. Put standards in place to maintain them

. Establish improvedinspection standards

through depth technical training &

thorough understandingof equipment and

processes

.Standardize systemsand methods

. Implement qualityand process control

. Develop robustorganization and

culture that is capable of

SELF-MANAGEMENT

Restore ExternalDeterioration

. Classify trend or non-trend cases. What is a trend?. Why not detected before breakdown? . * Life Span = MTBF

THE FOUR PHASES TO ZERO BREAKDOWNSTable 2

Outline of Breakdown Countermeasure Approach

RP1

RP2

# ofbreakdowns

RP: Replacement Period

Restore NeglectedDeterioration

(handling of hidden defects)Eliminate Accelerated

Deterioration

. restore basic conditions

. adhere to use conditions

RP1

. correct design weakness

. improve proper part loading

. select parts that fit conditions

RP2

Lengthen Specific Parts Life

Eliminate SporadicFailure

.operation/repair mistakes

RP1RP2

Estimate Parts Life,Restore Periodically

. Improve maintainability

Detect AbnormalityBy The Senses

RP3

RP1

RP2RP3

RP4

X

Condition Based Maintenance

. Analyze cross section surface

. Analyze gear material wearing

. Analyze gear mesh

Condition Monitoring,Machine Diagnosis

Analyze Critical Failure,Estimate & Lengthen

Parts Life

Phase 1

Steps 1-3Reduce Variations of

Parts Life Span*

Phase 2

Steps 4Prolong Life Spanof Specific Parts

Periodically ReplaceDeteriorated Parts

Steps 5

Phase 3

Predict PartsFailure and Replace

Steps 6

Phase 4

AM or Jishu-Hozen of an assembly line

The AM work progress for Assembly line is different. The Manual work done by individual will be treated under IE

methodology. There is scope for improvement in Productivity, safety and

Quality. The time taken and the fatigue developed both should be

taken into consideration.

Five Major Losses which hamper Human work.

Management losses- Waiting for materials, instructions etc.

Motion Losses- Losses due to skill difference, poor layout etc.

Arrangement losses-Multi-process or Multi-stand operations, line balancing.

Loss resulting due to lack of automation-Lifting, moving, turning etc

Monitoring and adjustment losses-Monitoring for Quality defects or Flow of materials.

Seven Major losses of Human Motion.

Waiting time losses- Standing or watching( Management Loss), poor

line balancing. Walking time losses- Just walking and not doing any work. Transportation time losses-Movement of materials by lifting or on a

trolley. Searching time losses- Poor identification of parts, no visual controls. Judgment time losses- poor visual controls, lack of skills and lack of

procedures. Set up and adjustment Losses- Positioning or adjustment is done. Defect losses- not fitting properly, not tightening and creating defects.

So, how do we carry out improvement

Proper storage of parts and methods of Indication.

Preventing Quality Defects.

Preventing assembly defects.

Storage of parts and methods of indication

The storage of parts to be the nearest to the place of assembly. Separate parts in separate bins or storage. “First in First out” (FIFO) method to be followed. Proper inventory control and levels to order new material. Marking for the parts storage-Type and size ( for Kan-ban proper

arrangements) Provide Work-abnormality indication lamp, Transportation calling

lamp, work in progress indication lamp and abnormality indication lamps.

Preventing Quality Defects

Steps to prevent careless errors- Steps to make erroneous actions impossible: Poka yoke, fail safe, can not fit other way round etc.

The Precision of parts to be checked beforehand. Prompt flow of information. Jigs and tools should be checked for functioning and accuracy. Excellent work distribution, process formation and line balancing

required. Layout of assembly line. Work Standards to be provided on time and training.

Preventing assembly defects

Remove Unnecessary tools and repair tools. Jigs and tools placed in storage locations should be easy

to see, easy to remove and easy to put back. Position and heights of parts shelves, size and shape and

replenishment of parts to be made very functional. Excessive production and Tentative placements should be

avoided. Work standards and criteria to be provided. Visual controls to be in place.

Improvement of Human motion losses.

Providing proper guiding of parts into assembly.Usage of pneumatic tools and other tools.Introduction of signboards to highlight and keep in

proper angle and height.Synchronizing the main conveyor and the dolly.Taking care of ergonomics in lifting, tightening,

bending and holding tools.Both hands to be used.

Six Steps for Implementing Jishu-Hozen in assembly line

Step 1 -Initial Preparation.Step 2- Counter-measures for places of difficulty.Step 3- Setting Temporary standards.Step 4- Overall Inspection.Step 5- Attainment of balance in a line.Step 6- Putting standards in order and adherence

to standards.

Step-1: Initial Preparation and Improvement.

Remove all unnecessary things.Removal of dust, grime and dirt.Improve parts shelves, boxes, work stands,

equipment and tools.Expose defects- Put Defect tags.Identify storage places.Preparation of Identification marks.

Step 2: Countermeasures for the Places of difficulty.

Countermeasures for the sources of dust and dirt.Measures for handling heavy items.Easy to use equipment and tools.Steps for doing parallel operations.Improvements to remove errors by carelessness.Assessing the gains achieved by these

improvements.

Step 3: Setting temporary standards.

Practicing Visual control. Preparation and implementation of Inspection standards. Preparation and Implementation of operating standards. Improvement of line efficiency (OEE).

Step 4:

Optimization of tools and jigs.Arrangements for prevention of careless errors.Work facilitation.Elimination of deterioration tools.Elimination of inaccurate jigs and measuring

instruments.

Step 5: Attainment of balance in a line.

Optimization of work distribution. Introducing parallel operations. Improvement of parts feeders. Improvement of heights of shelves and dispensing

methods. Optimization of parts placement methods. Optimization of inventory. Optimization of human motions.

Step 6: Putting standards in place and adhering to standards.

Prevention of quality defects.Elimination of dispersion of motions.Fixation of rhythmical work.Set up time reduction.Improvement of skills.Start up and stop optimization.

What is Phase Zero

Phase Zero means time period in which Planning to Implement TPM is done.

Phase in which consensus of the critical Mass is developed.

Phase in which a Model is developed for Managers to understand “Power of Zero and Power of 100” better.

Phase in which “Where are we today” is understood. Phase in which Resources are identified. Phase in which Final decision to implement with clear

“Vision, Mission and Strategy” are drawn.

Leadership Model work.

Go to your model and meet in your team before starting any work.

Observe the your module while it is in operation. Look at all activities and make your plan. Document all data and try and analyze the data. Take before pictures or video shooting.

Model work contd.

Meet the Team leader and your facilitator. Have team member roles identified. First discuss about safety procedure. The start your work as mentioned in the steps. Give importance to 16 major losses. Identify your team goals. Identify all opportunity areas.

Leadership model Contd.

Put defect tags and keep them in place for some time. Meet in your team and discuss all opportunities. Do brain storming and come out with you action plan. Please do not get into line balancing until you would have

worked on all work stations. Make one point lessons to learn from each other. Identify Kaizens and document them.

Role Of Leadership

TPM is not just Bottom up exercise. TPM needs a great amount of Leadership initiative and

drive. There is no separate Leader; it is the same Plant leader

who will lead TPM. Leader has to get convinced first. TPM is “learning by doing” and “Lead by coaching” Leader has to come out with a clear “Vision”

understood by all in the Plant.

What is a “Leadership-Model”

A machine or Part of a machine to practice Autonomous Maintenance and Learn while doing.

An opportunity for the leaders to understand “zero defect” and “100% employee involvement” Concept.

An opportunity to understand the resources needed to achieve the Vision.

An opportunity to understand the issues and problems better.

An opportunity to build a cohesive team.

More on “Leadership-Model”

Leaders need to take time to do this important thing. This is the only opportunity to demonstrate to all

employees, the right way to do things and show the potential of TPM.

This shall be the show piece in the whole plant. This is a learning ground. This will take quite some time(3-4 months). A great opportunity to do integration of all pillars.

Six steps of Phase zero

Formally announce the decision to implement TPM. Introductory Education and publicity campaign. Create TPM Organization. Establish Vision, Mission, Strategy and Goals. Prepare a Draft Master Plan to implement TPM. Kick Off.

Formal Announcement

Top Managements firm decision.

Announce in company magazine.

Take all the suppliers and vendors in confidence.

Let employees understand clearly the purpose.

Introductory Education

TPM Overview training for all Managers.

Leadership Model to be identified and Started.

Slide shows to all employees teams.

Education on team work.

Posters and pictures for common employees.

TPM Policies and Goals

Plant Leader to share the vision.Plant to Identify and draft the mission and Strategy.Establish the current Performance Indices.Establish very stretching Goals for three years.Forecast them by Goals for each year.

Master Plan for TPM

The TPM committee shall prepare the Master plan. This is a draft Master Plan and will be refined after Leadership

Model. Master Plan is a very important document, but dynamic in

nature. Master plan will cover activities from Kick off till the end. Master Plan will identify mile stones.

Structure to implement TPM

No Major changes are needed. Plant Manager has to get fully involved. Identify one TPM Manager full time to support Plant

Manager. Identify leaders for each Pillar (AM, FI,PM). Identify Leaders for each team or circle. Working hours regulation is key.

Kick Off

Kick Off is very important milestone. Plant will invite all important affiliates, suppliers and contractors. Some plants make it a big event by involving families. However it should be felt as a great event by all employees. There is no looking back after Kick off. In Japanese plants it is like oath taking by Leaders and Key People.

Dos and Don’ts for Phase Zero

Do a good job of convincing people in Phase zero. Do give a lot of importance to preliminary education. Do a great job on the Leadership Model. Do not be in a great hurry to do kick off. Do not cut the time spent on education and training. Do not Transfer key people at least for one or two years.

What is outside consultants role.

Major contribution in Phase Zero- guiding, training, establishing structure.

Training in Pillar Processes. Training in basic and advanced skills needed. Training in Problem solving tools and technologies. Conduct Step audits and Phase audits.