total productive maintenance (tpm) -...
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Total Productive Maintenance (TPM)
Total Productive Maintenance (TPM)
Practical Process Improvement Practical Process Improvement Practical Process Improvement
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TPM blitz TPM blitz
Kaizen Workshop Purpose:The purpose of this Kaizen Blitz is to improve the ability to respond to customer’s demand through improved asset utilization, workplace organization and visual management.
Objectives:1. Complete Phase 1 & 2 TPM improvement activity2. Improve OEE by 25% with 2 months3. Improve Workplace Organization and Visual Management
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TPM DefinitionTPM Definition
TPMTPM is a process that maximizes the
productivity of equipment for its entire life.
TPMTPM fosters an environment where improvement efforts in Safety, Quality, Cost,Delivery and Creativity, are encouraged, through the participation of employees.
Total Productive Maintenance
“Total” means = ALL Employees
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AgendaAgenda
Day 1: Classroom training Phase 1 & 2, facility measurements & evaluations.
Day 2: Classroom training Phase 3 & 4, maintenance measurements & evaluations, for better maintenance work flow.
Day 3: Focused cleaning, sorting, inspection, modifications and/or laying out areas,for better maintenance work flow.
Day 4: Improve safety, calibration, data collection, & lubrication in facility and maintenance areas. Evaluate and measure.
Day 5: Plan long term improvements. Team to present successes and action items.
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1. Stabilize Failure Intervals
2. Improve Equipment Productivity
3. Maintenance Excellence
4. Predict Equipment Life
Ratings: 0 = No obvious application of standard 1 = Some evidence of application of standard 2 = Fully applied standard
.13
.00
.16
.16
Average
Current StateCurrent State
Was Now.39
.27
.16
.16.11 .24
66
Current StateCurrent State
77
Fluid lines & fittings leakFluid lines & fittings leakGrease fittings are dry & not coveredGrease fittings are dry & not coveredAir filters are not presentAir filters are not presentPump motors are coated with dirt / contaminationPump motors are coated with dirt / contaminationElectrical cabinet fans are coated with dirt/dustElectrical cabinet fans are coated with dirt/dustGauges are not usable, dirty and not labeledGauges are not usable, dirty and not labeledElectrical connections are loose & wires are damagedElectrical connections are loose & wires are damagedChemicals migrate causing contaminationChemicals migrate causing contaminationFasteners are corroded / strippedFasteners are corroded / strippedGuards / shields are loose or missingGuards / shields are loose or missingExcessive solid / liquid waste is underneathExcessive solid / liquid waste is underneathRoutine inspection difficult due to accessibilityRoutine inspection difficult due to accessibilityNo ownership by employeesNo ownership by employeesEHS issuesEHS issues
Equipment Condition
Current StateCurrent State
88
Top 5 FailuresTop 5 Failures
Defect % Solution
1
2
3
4
5
(Based on Team experience)
Degaste Bomba/ Friction in the pump 35% Prevent media from entering pump
Poleas & Bandas/Pulleys & belts 20% Inspect/replace based on run time
Ensure ample supply of cold water from chiller
Sello Mechanico en Molino/Seal on the Mill 5%
Fugas de tanque/Leakage from tank
Operadore no disponable 100% / Operator not available
5%
35%
Fix/replace pipes
Create checklist/walk pattern/inspection points
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Team in ActionTeam in Action
1010
Team Azub Date: 11/11/2005 Page:______ of:______
Item No. Description of Problem Counter Measure
Person Responsible Due Date
% Complete Date Complete
5s actions
1
Excessive sludge, water, trash, rusty metal, dust
Clean entire plant/Limpiar todo la planta
TEAM, OPERATORS 11/11 11/11
2
Paint is peeling, stained Paint affected parts/Pintar partas necessarias
TEAM, OPERATORS 11/11 11/11
3Slurry overflows from the Mill Repair float sensor/Instalar
sensor descarda MolinaSantiago Lopez 11/11 11/11
4
Gages air, water, temperature are unreadable Replace all affected gages Jose Martin
11/11 11/11
5 Leaking pipe under slurry tank Replace and re-seal pipes Edder Marlon11/11 11/11
6 No visual management indicators
Install signage(rotation, flow direction, equipment name, warnings) Jose Martin
11/11 11/11
OEE actions
7Agitator motors are clogged with dust which causes overheating and motor failure Clean and install filters Jorge Garcia
11/11 11/11
811/11
8 Slurry leaks from Mill pump housingChange Mill pump & rebuild old pump Gilberto Vazquez
11/11 11/11
9No indication of maintenance points (lube, fill, check, tighten) Number and list points to service Jose Martin
11/11
10Media enters the mill pump and causes premature wear on internal pump parts
Repair/ replace mesh in Mill and inspect between batches for damage Andres Medina
11 Critical parts are not always availableCreate list and purchase as required Juan Cuestas
12/1
12
Improper water temp causes seal failure on Mill
Clean chiller and install air filters
Jose Tolentino
11/11 11/11
13
Limited visibility to RPM controller (hidden in cabinet)
Re-mount controller on face of cabinet
Andres Medina
11/11 11/11
EHS actions
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Access to pulleys/belts on agitator is poor(employee can fall) Install metal ladder/platform Contractor
11/11 11/11
16 Gate on landing over the Agitator is missing Replace the gate Gilberto Vazquez11/11 11/11
17 Guards missing multiple places Clean/replace/repair guards TEAM, OPERATORS 11/11 11/11
18Agitator loading hatch causes excessive material spills
Add a chute that will support the bag of material Contractor
11/11 11/11
Sustain actions
19Gages, switches, sensors, filters etc do not get regular attention
Inspect/repair/clean gages, sensors, floats, limit switches, filters weekly Operators
11/11
20Preventatitve maintenance is limited due to available evaluation tools
Create Tool list for Preventative TPM (include thermography and ultra-sonic equipment Raul Hernadez
12/1
21Routine maintnence is not scheduled or performed consistently
Create and display schedule with weekly audit by leadership Jose Martin
11/21
22 No weekly 5s reviewWeekly 5s review performed and reviewed by leadership team Dimitri Makres
11/21
23 No defined strategy for TPM deployment
Leadership team to particpate in TPM 2-day strategy design/planning session (See Dimitri Makres
TBD
24 No historical OEE data availableBegin tracking daily uptime/downtime and reasons Raul Hernadez Start 11/21
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1111
Leaking pipes New pipe connections
Contaminated Motor Cleaned & filter installed
ImprovementsImprovements
One thread holding the joint together!!
1212
ImprovementsImprovements
Dirty water chiller Cleaned & filters installed
Gages replacedNon-working Gages
1313
ImprovementsImprovements
Need a ladder to grease Fittings accessible without ladder
Can you see the filter? Now you can
1414
Ladder installed
New Pump installed w/ guardSolid waste under pump
ImprovementsImprovementsDifficult accessibility to belts/PM
Guard removed
1515
RPM control in cabinet RPM control accessible
Cleaned areaDirty rags and trash
ImprovementsImprovements
Open door
Control visible with door closed
1616
Angled Feed Chute
Missing safety railing Repaired safety railing
ImprovementsImprovements
Messy load area Chute
1717
TPM Focused Improvement Objectives TPM Focused Improvement Objectives -- ResultsResults
Equipment: Acme Plant Date: week 11/7
Start Target 1st Day 2nd Day 3rd Day 4th Day 5th Day Post Event%Increase/Decrease
Space (sq. ft.)
Scrap/year(concentrate)
Walking distance (ft.)
Parts travel distance (ft.)
Noise level (db)
EHS issues Visual controls
O.E.E. (%) **5’S rating
4-phase development score
Throughput timeProcess cycle time
Changeover (Total time)
Exhaust air flow (CFM)
Mistake Proofing
Changeover (Total # )
49%1.32 3.3
61%
Avg .11
9 00 15
0
Avg .25 Avg .24
** Estimated OEE based on experiential data
Note: 1425 lbs concentrate ($2591) removed with this effort
Parts volume per day
69%
3000 lbs
3.4
10 100%100%20%100%
100%
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Learnings:
1) Keep area clean allows us to see problems before they occur2) Employees area critical to TPM success3) Start a new culture of owning the process4) Safety cannot be overlooked
Benefits:
1) Reduce/eliminate scrap to save estimated $ 5,400/year2) Problems can be observed more quickly
3) Operators safety is increased
4) Process reliability improved 20%
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Next Steps
- Complete open items from Newsletter
- Management Gemba walks to sustain changes
- Management training on TPM basics
- 5S blitz on the maintenance area/warehouse (5s score is 1.67)
-TPM program design and deployment strategy(ref. Phase 3 Maintenance Excellence / Phase 4 Predictive Maintenance