1

TPM in the connected factory

Japan Institute of Plant Maintenance

Senior Researcher Zensuke (Zen) Matsuda

Dec. 201

UK TPM Seminar

T.. Total P.. Productive M. Maintenance Management TPM is the holistic, structured and quantifiable methodology to seek productive excellence by eliminating losses. TPM is a concept rejuvenating itself with experience of many users.

2

TPM

Actual Scene/Thing

Humanity

Zero loss

Sustainability

Preventive

Rejuvenation

3

History of TPM 1950 1960 1970 1980 1990 2000 2010

1982

1971

2000

1951

Breakdown Maintenance

Preventive Maintenance

TPM(21st Century)

TPM (Total Productive Maintenance)

TPM (Company- wide)

1960 Productive Maintenance Preventive

Operator Participated

Entire Company

Innovative

Awarded factory / Industrial Classification

Machine work & Assembly Industry 1,341 Process Industry 1,838

Automobile and Other Motor Vehicle 123 Iron and Steel & Non-Ferrous Metal Products

221

Automotive Parts & Accessories, and Transportation Equipment

642 Chemicals 335

General Industrial Machinery & Equipment, Precision Apparatus

127 Textiles 84

Semiconductor & Electronic Equipment 213 Rubber & Plastic Products 196

Consumer Electronic Appliances, Information Communication Electronics Equipment

99 Food & Beverage 503

Fabricated Metals 103 Drug & Medicine 26

Housing & Woodwork 34 Pulp & Paper 166

Printing 98

Cement & Ceramic Products 93

Electric Power & Gas, Petroleum and Coal 118

Others 70

Year : 1971-2015 Total 3,249.

4

5

TPM Awards to Tetra Pak

Global Leaders Initiative Award

World Class Award

Tetra Pak Production d.o.o.

Gornji Milanovac, Serbia

23 March 2016 Tetra Pak Home Page :Tetra Pak Receives the

Worlds Most Prestigious Manufacturing Award.

Mr. Lars Wennberg

Vice President

Terta Pak

Empowered people deliver

breakthrough results!

http://www.tetrapak.com/

about/newsarchive/tetra-

pak-receives-the-worlds-

most-prestigious-

manufacturing-award

Keynote Speech

Zen-in sanka

(All members

Participation)

http://www.tetrapak.com/about/newsarchive/tetra-pak-receives-the-worlds-most-prestigious-manufacturing-awardhttp://www.tetrapak.com/about/newsarchive/tetra-pak-receives-the-worlds-most-prestigious-manufacturing-awardhttp://www.tetrapak.com/about/newsarchive/tetra-pak-receives-the-worlds-most-prestigious-manufacturing-awardhttp://www.tetrapak.com/about/newsarchive/tetra-pak-receives-the-worlds-most-prestigious-manufacturing-awardhttp://www.tetrapak.com/about/newsarchive/tetra-pak-receives-the-worlds-most-prestigious-manufacturing-awardhttp://www.tetrapak.com/about/newsarchive/tetra-pak-receives-the-worlds-most-prestigious-manufacturing-awardhttp://www.tetrapak.com/about/newsarchive/tetra-pak-receives-the-worlds-most-prestigious-manufacturing-awardhttp://www.tetrapak.com/about/newsarchive/tetra-pak-receives-the-worlds-most-prestigious-manufacturing-awardhttp://www.tetrapak.com/about/newsarchive/tetra-pak-receives-the-worlds-most-prestigious-manufacturing-awardhttp://www.tetrapak.com/about/newsarchive/tetra-pak-receives-the-worlds-most-prestigious-manufacturing-awardhttp://www.tetrapak.com/about/newsarchive/tetra-pak-receives-the-worlds-most-prestigious-manufacturing-awardhttp://www.tetrapak.com/about/newsarchive/tetra-pak-receives-the-worlds-most-prestigious-manufacturing-awardhttp://www.tetrapak.com/about/newsarchive/tetra-pak-receives-the-worlds-most-prestigious-manufacturing-awardhttp://www.tetrapak.com/about/newsarchive/tetra-pak-receives-the-worlds-most-prestigious-manufacturing-awardhttp://www.tetrapak.com/about/newsarchive/tetra-pak-receives-the-worlds-most-prestigious-manufacturing-awardhttp://www.tetrapak.com/about/newsarchive/tetra-pak-receives-the-worlds-most-prestigious-manufacturing-awardhttp://www.tetrapak.com/about/newsarchive/tetra-pak-receives-the-worlds-most-prestigious-manufacturing-awardhttp://www.tetrapak.com/about/newsarchive/tetra-pak-receives-the-worlds-most-prestigious-manufacturing-awardhttp://www.tetrapak.com/about/newsarchive/tetra-pak-receives-the-worlds-most-prestigious-manufacturing-awardfile://upload.wikimedia.org/wikipedia/en/e/e0/Tetra_Pak.svg

Factory Supply Delivery

Equipment

Producer

Material

Supplier Customer

Planning

Product

Development

TPM Activity Progress

Company

Administration

Connected

Business Chain

Outsourcing

Io

IoT: Internet of Things

Cyber Physical System

AI: Artificial Intelligence

Asset Management

Data Analysis Standardization

ISO/IEC

6

7

KMI/KPI/KAI(Example)

KMI : Key Management Indicator KPI : Key Performance Indicator KAI : Key Activity indicator

OEE

Claim, Quality

Cost Reduction

Lead Time

Save Energy, etc.

Skill Management

Co-development with Customers, FMEA,FTA

Quality of Modules, Supplier Assessment, QFD

KAIZEN, New Material Evaluation, etc.

MAKIGAMI Process Step Reduction), VSM

Energy Conservation, Wastes Reduction

:Number of Kaizens and Activities

Seminar, Qualification, Certification

Defect Tag, OPL, PM-Analysis, RCM

Accidents Near Accidents finding, Essential Safety Design

Revenue Profitability Safety Quality

OPL: One Point lesson

PM-Analysis

P:Phenomena/Physical

M:Mechanism/Machine

/Method/Material/Man

RCM: Reliability-Centered

Maintenance

FMEA: Failure Mode

Effects and Analysis

FTAFault Tree Analysis QFDQuality Function Deployment

VSM: Value Stream

Mapping

New Product Ratio

KPI

Lo

ca

l Fa

cto

ries

S:Safety

P:Productivity

Q:Quality

C:Cost

D:Delivery

E:Environment

M:Moral

KAI

KPI

KMI (.)

KMI (New Product)

KMI/KPI/KAI & Loss-Cost Matrix

8

KMI (Profit)

Cost Structure Cost Reduction Target

Loss Finding

Kaizen

KPI

Evaluation

Strategy

plan

do

check

action

Leadership

KMI (Revenue)

KAI

Management

Standardization

Loss Cost Matrix

SOP

(Standard Operating Procedure)

KMI :

Key Management

Indicator KPI :

Key Performance

Indicator KAI :

Key Activity

indicator

9

KPI Performance Improvement/Year

Data: From 2012TPM Award winners (World-classConsistent) Energy: 2014 TPM Award winners

Customer

Complaints

%/Year

12%

OEE

1.7%

%/Year

+2%/Year -12%/Year

Accidents

%/Year

9%

-9%/Year (Minor Accidents)

-10

-9

-8

-7

-6

-5

-4

-3

-2

-1

0

Energy

-4.9%/Year

4.9%

%/Year

TQM/TPM/TPS

10

Respect

for

Humanity

TPS

KANBAN (Index Board)

TQM TPM

Quality Function Deployment

Loss-cost Matrix

Just in Time

Autonomation

Autonomous Maintenance

Loss Zero

Statistical Process

Control

Policy Management

ANDON (Signboard)

KARAKURI KAIZEN

QC 7 tools

Efficiency Reliability

Excellence

OEE: Overall Equipment

Efficiency

Heijunka (Process Smoothing)

Waste/ Unevenness/ Strain Elimination

Poka-yoke (Failsafe)

Tanpin Kanri (Management by single product)

GENBARYOKU (Wisdom of work place)

(Total Quality Management) (Total Productive Maintenance)

(Tyota Production System)

11

TPM: A Foundation for Asset Management

MAINTENANCE

TECHNOLOGY

Sept. 2014

Editor:

Bob Williamson

CMRP, CPMM,

and Member of

Institute of

Asset Management

12

Past

Present

Future

Target

Present

Situation

Gap=Loss TPM

ISO55000s

Productivity is an attitude of mind.

It is the will to improve on the present situation, no

matter how good it may seem, no matter how good it

may really be.

(European Productivity Agency1958)

Asset Management & TPM

Line of sight

Zen-in sanka (All members Participation)

Top Down and Bottoms Up for Excellence

13

Top Goal

Middle Target

Operation Motivation

Line of sight

Zen-in sanka (All members Participation)

If abnormality happens, operators are authorized to stop a line, and find out a true cause in "Zen-in sanka" way.

Global Innovation with IoT

Industr