tpm overview and am workshop
TRANSCRIPT
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TPM Overview and Autonomous Maintenance
Workshop
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1. Understand the concept and philosophy of TPM 2. Learn the 8 Pillars of TPM 3. Understand the key concepts of Autonomous
Maintenance activities 4. Learn the step by step implementation plan of
AM activities 5. Learn the usage of activity boards, meetings
and one point lessons to promote TPM goals 6. Understand the critical success factors in
sustaining Autonomous Maintenance activities on the shop floor
Course Objectives
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Total Productive Maintenance (TPM) is a method to achieve maximum equipment effectiveness
through employee involvement
Management + Operators + Maintenance
What is TPM?
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Why Is TPM Important? TPM Will improve
teamwork skills and flexibility between operators and maintenance technicians
TPM will improve equipment availability (uptime)
TPM saves money
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Equipment is filthy and stays that way
Oil and lubricant leaks are common; lubricators are empty
Rotating parts and moving surfaces are encrusted with chips and raw materials
Common Features of Workplaces with Poor TPM Practices
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Machine failures have many hidden causes
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Eight Pillars of TPMTPM GOALS: 0 Defect / 0 Breakdown /
0 Accident
5S & Visual Management
Auto
nom
ous M
aint
enan
ce
Focu
sed
Impr
ovem
ent
Early
Equ
ipm
ent
Man
agem
ent
Qual
ity
Mai
nten
ance
Educ
atio
n &
Trai
ning
TPM
in th
e Offi
ce
Safe
ty &
En
viro
nmen
tal
Man
agem
ent
Plan
ned
Mai
nten
ance
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Focused Improvement
Autonomous Maintenance
Planned Maintenance
Education & Training
The Four Key TPM Pillars that are Critical for Equipment Reliability
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Autonomous Maintenance is maintenance performed by operators
Basic maintenance that can easily be performed on a daily basis, e.g. inspection, cleaning, lubrication, etc.
Learning about the equipment to understand how it works and be able to spot signs of trouble
An employee engagement program as part of the Lean/TPM initiative
What Is Autonomous Maintenance?
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An activity to keep operators busy when product demand is low
Doing a favor for maintenance department
Performing basic maintenance without a purpose
Making operators into skilled technicians
What AM Is Not?
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Operator Maintenance
AM is a Paradigm Shift!
We maintain
TPM Attitude
Operator Maintenance
I use I maintain and fix
OLD Attitude
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AM- Who Does What
Predictive Maintenance
Breakdown Maintenance
Maintenance Activities
Preventive Maintenance
Robustness Improvement
Start Up & Yield Loss
Defects & Rework
Condition Based Servicing
Trends Measurement & Control
Effective & Appropriate Repairs
Routine Maintenance
Cleaning-Refurbishing
Daily Equipment Care
Lubrication- TighteningDaily Inspection
X
X
X
X
X
XX
X
X
X
X
Prodn Maint
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We Need a Culture Change!
Work Systems & Processes
Behavior
Attitude
Culture
By improving equipment & processes….
Changes the way we act……
And the way we think…..
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Organization-led activitiesSupported by company and TPM Office
Use of audits Determine full implementation of each step Provide feedback on strengths and
weaknesses Clarify what needs to be achieved and best
way to do it Use of activity boards Meetings and reports
Characteristics of AM Programs
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KEY CONCEPTS
• Shop floor based activities
• Operator conducted• Operator enhancing• Team Activity• Autonomous
management• TPM Foundation• Part of the job!
3 Key Tools for AM3 KEY TOOLS
• Activity Boards
• Meetings
• One Point Lessons
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1. Ability to detect abnormalities2. Ability to correct abnormalities and
restore function3. Ability to set optimum equipment
conditions4. Ability to maintain optimum equipment
conditions
Four Equipment Related Skills for Operators
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1. Clean and inspect2. Eliminate problem sources and inaccessible
area3. Draw up cleaning and lubricating standards4. Conduct general inspections5. Conduct autonomous inspections6. Standardize through visual workplace
management7. Implement autonomous equipment
management
7 Steps of Autonomous Maintenance
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Initial cleaning of the machine
Identification ofAbnormalityHard to access areasSources of contaminationUnsafe conditions
1. Cleaning and Inspection
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Cleaning is inspection Inspection is finding problems Problems demand restoration to original proper conditions and improvement to prevent recurrence
Initial Cleaning is the Foundation of Autonomous Maintenance
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Dust Dirt
Leak Rust
Loose
Identification of Abnormalities
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Damaged Deformed
Noise Non Standard
Vibration
Identification of Abnormalities
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Worn Out Missing
Misalignment Shaking
Identification of Abnormalities
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Bolts and Nuts/ JointsLubricationTransmissionHydraulicsPneumatics – gas systemElectricalSafety
Where To Find Them?
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Missing Loose Shaking Non Standard Bolts / Washers Corroded Damaged Excess / low length Paint on threads and head
Abnormalities in Bolts & Nuts
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Sample Bolts/Nuts Abnormalities
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Sample Bolts/Nuts Abnormalities
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Sample Bolts/Nuts Abnormalities
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Sample Bolts/Nuts Abnormalities
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Slackness Tight Damaged Misalignment Noise Pulley/ belt/ gear/ shaft damaged Belt missing Tracking Eccentricity Play
Abnormalities in Transmission
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Abnormalities in Transmission
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Oil level low / high Oil contaminated Oil pressure low / high Oil temperature high Jerks / Vibration Line damage Line not routed properly Noisy pump Pressure gauge not working Oil leak
Abnormalities in Hydraulic System
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Abnormalities in Hydraulic System
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Air / gas leak Line damage Line not routed properly Sluggish cylinder movements Filter not drained of moisture Lubricator level low / high Oil flow rate high
Abnormalities in Pneumatic System
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Abnormalities in Pneumatic System
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Loose connections Hanging wires Cable not routed properly Cable gland loose Motor generating noise Motor generating more heat Exposed wires Panel inlet filter block Panel / junction box open Screws missing Dust / dirt Connections with open wires
Abnormalities in Electrical System
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Abnormalities in Electrical System
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Abnormalities in Electrical System
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1. Don’t be afraid to get your hands dirty during cleaning
2. Remove years of build up grime3. Open covers and lids on areas you have
never checked before. Clean the dirt off every hidden recess of the equipment
4. Don’t just clean the main body of the machine. Remove the grime from auxiliary equipment such as conveyors, gauges, electrical cabinets, and the insides of oil tanks
Tips for Cleaning
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1. Look for loose fastenings, slight vibrations, abnormal temperatures and other problems that can only be detected by touch
2. Watch for worn out pulleys and belts, clogged suction filters, grime on sliding surfaces, and other problems that may lead to functional failures
3. Are cleaning, lubricating, and checking easy to do? Do any large covers get in the way? Are oil inlets located conventionally?
Tips for Inspection
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Unsafe Places
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How to develop Stage 2? Priority of countermeasures Types and sources of contamination Countermeasures for difficult to clean areas Where-where and why-why analysis Use corrugated paper and acrylic cover to
prevent dispersion Use hinge doors instead of fastening screws for
ease of opening Keep records of equipment modifications Review unresolved issues
2. Eliminate problem sources and inaccessible areas
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Inaccessible Areas
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Elimination of Problem Source
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What is lubrication control? Preparation by the Maintenance Department Identify lubricating points and surfaces Allocate routine lubrication tasks Draw lubrication system flowcharts Set tentative lubrication standards Remedy defective area and difficult lubricating
areas Set cleaning and lubrication standards Thoroughly implement a color lubrication control
system
3. Establishment of a LubricationControl System
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Lubrication Controls
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Lubrication system not working No grease in reservoir No visibility No oil in gear box Lubrication level low/ high Grease / oil leak Without grease nipple and cap Reservoir tank open Excess greasing Oil / grease dust contamination
Abnormalities in Lubrication
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Abnormalities in Lubrication
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Abnormalities in Lubrication
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4. Conduct General Inspection
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Conduct General Inspection
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5. Conduct Autonomous Inspection
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Template 1 – List of Abnormalities
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Template 2 - Checklists
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Template 3: Audit Plan
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Template 4: Status of Abnormalities
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Template 5 – Break down register
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The concept of making a workplace more effective by making the current condition of a workplace obvious at a glance
Visual management enhances the smooth flow of information by using visual and audio signals instead of texts or other written instructions
It includes a set of techniques that makes operation standards visible so that people can follow them more easily
6. Visual Management
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Putting up displays and charts to impress corporate visitors or customers
Cluttering empty walls with visuals as if decorating for a birthday or Christmas party
A one time effort, only to have the visuals or information become outdated over time
Isolated from management standard work
What Visual Management Is Not
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Why Visual Management
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Applications of Visual Management
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Visual Displays (Office)
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Examples of Visual Controls
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A Good Standard Should Be Visual
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Visual Management
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Visual Management
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Visual Management
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Process never ends◦ Metrics◦ Audits
Each process post Results (actual) against Goal (target)◦ Zero lost time accidents◦ Zero Defects◦ Zero Breakdowns◦ Zero set up time or at least < 10 minutes
7. Autonomous Management
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1. Proper education and training Are the operators certified? Who certifies them?
2. Development of four equipment related skills3. Establishment of AM schedule for each
operator4. Autonomous management using activity
board and meeting5. Identifying and reporting problems6. Participation in problem solving and OEE
involvement
Key Implementation Points of AM
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Active leadership for TPM initiative AM is owned by Production Department and
supported by Maintenance Department Proper operator training, education and
skills certification The time required for cleaning and
lubrication must be included in the daily schedule
Supervisors need to ensure that AM activities are performed
How to sustain AM?
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Critical Success Factors Engaging
employees Aim for early
success Providing active
leadership Share success
stories Rewards and
recognition Continuously
improve OEE
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THANK YOU!