TPM

WAYFORWARD

STEP-1 DECLARATION BY TOP MANAGEMENT

1. INTENTION TO IMPLEMENT TPM -PUBLICISE IN IN HOUSE NEWS BULLETIN - LETTER TO EACH EMPLOYEES - PERIODICAL SMALL ARTICLES ON TPM ( EITHER IN COMPANY MAGAZINE OR

THROUGH E-MAIL OR THROUGH DISPLAY ON NOTICE BOARDS)

2. ADDRESSING ALL PEOPLE IN A MEETING

STEP-2 TPM EDUCATION, TRAINING & COMPAIGN

1. AWARENESS TRAINING TO BALANCE PEOPLE

2. PREPARE TRAINING CALENDAR & MONITOR TRAINING

3. SLOGANS/SONG/POEM/POSTER COMPETITION

4. EVALUATION OF UNDERSTANDING OF TPM( AFTER COMPLETION OF AWARENESS TRAINING )

STEP-3 TPM PROMOTION OFFICE

1. TPM SECRETARIATE HEAD-DEDICATED PERSON

2. FORMATION OF STEERING COMMITTEE

3. FORMATION OF TPM CIRCLES4. FORMATION OF 8 PILLAR SUB-

COMMITTEES

President

Plant Manager

Section Chief

Sub-Section Chief

Supervisor

Front-line Worker

Company wide TPM Promotion committee

Plant TPM promotion committee

Section TPM promotion committee

Foreman TPM promotion committee (Leader Meeting)

Small group formed on the production floor (PM circle)

FOCUS IMPROVMNT sub-commmitteeAUTO.MAINT sub-committeePlanned Maint. sub-committeeInitial flow control sub-committeeQUALITY MAINT. sub-committeeOffice improvement sub-committeeEducation and Trg. sub-committee

Safety and hygiene sub-committee

TPM Promotion Office

Typical TPM Organization Chart

STEP-4 POLICY & GOALS

1. PREPARE TPM POLICIES -POLICY PRINTING ON 4’x 5’ – 4 NOS. -DISPLAY AT FACTORY GATE -ADMINISTRATION BLDG -OTHER PROMINANT LOCATIONS IN THE PLANT -PRINTING OF POCKET CARDS AND DISTRIBUTION TO

EACH EMPLOYEES2. IDENTIFY 8 MAJOR LOSSES & CALCULATE OPE OF

PILOT MODEL AREA AND ALSO OF OTHER UNITS3. PREPARE ACTION PLAN TO REDUCE LOSSES4. PREPARE IMPROVEMENT PLANS/TARGETS FOR

THREE YEARS AREAWISE,YEARWISE & MONTHWISE

EXAMPLE OF BASIC TPM POLICY & GOALS

•WITH EVERYONE’S PARTICIPATION, TO AIM FOR ZERO BREAK DOWNS AND ZERO DEFFECTS AND SEEK TO MAXIMISE OVERALL EQUIPMENT EFFECTIVENESS

•TO CREATE A WELL ENGINEERED EQUIPMENT AND USE IT TO BUILD IN QUALITY

•TO DEVELOP EQUIPMENT COMPETENT PERSONNEL AND HAVE THEM EXERCISE THEIR FULL POTENTIAL

•TO CREATE LIVELY AND ENERGETIC WORK PLACE

BASIC TPM POLICY

FY 1986 POLICY

FY 1987 POLICY

FY 1988 POLICY

1.Build a profitable corporate culture2.Promote a “ cut total cost by half “ campaign3.Promote TPM

SEPTEMBER 1988 TARGET

( Relative to April 1986 baseline)

No of failures: 1/100 or less

No of Minor stops : 1/20 or less

MTBF between minor stops : 4 h or more

Processing Productivity : 50% or higher

Material wastage rate : 1/3 or less

Total cost : 60 % or less

No of shut down accidents : 0

ANNUAL POLICY AND COMPANYWIDE TPM GOALS

OBJECTIVE1. Reduction in equipment

failure

2. Equipment failure rate

3. Occurrence of equipment failure

4. Down time

5. Overall equipment efficiency

6. Improvement of productivity

7. Reduction of rework and quality defects

8. Energy saving

9. Number of employees KAIZEN suggestion

10.Labour accidents

938/month

1.03% / 100hrs

1.59%

5,800hr/mon

88.8%

113%

0.7%

100%

2.1 / yr/ emp

11/yr

< 10/month

< 0.1%/100hrs

< 0.2%

< 1200 hr/mon

> 95%

> 169%( 50% rise)

< 0.1%

< 70%

60/ yr/ emp

0 / yr

ACTUALRECORD TARGET

STEP-5 MASTER ACTION PLAN

• TO PREPARE MASTER ACTION PLAN INCLUDING ALL ACTIVITIES AND ALL 8 PILLARS

• INCLUDE MODEL AREA WORK ALSO

TPM Master Plan ( Example )

Planned maintenance (Zero-failure)

“Kobetsu-Kaizen” (Elimination of

losses)

“Jishu-Hozen” activities by production department

Establishment promotion organisation, overlapping small groups in an hierarchical system & promotion secretariat

Set Policy Target, Slogan, and Achievement goal Work out master plan

Outline

Steady application stage

Full development stage

Implementation stageIntroduction stage

9089888786YearItems to be promoted

PM award Screening

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Organisation of KAIZEN teams

Selection of KAIZEN theme

KAIZEN activities (prior development of pilot model Horizontal replication

Step 1 Step 2 Step 3 Step 4 Step 5,6 & 7

Promotion activities (TPM news, contest using Activities status board, Presentation of activities, etc.

Step 7 development Education to transfer the general inspection method

Establish the planned maintenance system Classification of major items, time-based maintenance, Predictive maintenance

Lubrication and spare parts control system (Prior development of pilot model

Equipment zero-failure campaign (Prior development of pilot model Horizontal replication

Horizontal application

Overall equipment efficiency 1.5 times improvement plan

TPM

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(Nov

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Education and training

Safety management activities

Office operation improvement

“ Hinshitsu-Hozen” (Zero-defect)

Initial production and flow control

Steady application stage

Full development stage

Implementation stageIntroduction stage

9089888786Items to be promoted Year

© JIPM, 1987

DevelopmentEstablishing the initial production and flow control system Trial

DevelopmentEstablishing the initial production and flow control system and standardization

Trial Collection and application of MP information

Accumulation and utilization of information

Matrix 3M analysis Countermeasures against “fuguai” chart

FME, PM Analysis

Counter-measures

KAIZEN standardization

<Horizontal development>

Matrix 3M analysis Countermeasures against “fuguai” chart FME, PM Analysis Counter-

measuresKAIZEN

standardization

Step 1 Step 2 Step 3 Step 4 Step 5

KAIZEN of production management system

Development of 5 steps in office operation improvement Development of 4 steps in warehouse and storage management

“Sawayaka” campaign

Safety general inspectionCentral safety inspection manual

Support for “Jishu-Hozen” activities

Daily safety management activities

Individual ability developmentEstablishing education system

Maintenance skill training

Product :

Equipment :

Intro

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Simplification of accounting-related procedures

TPM

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TPM Master Plan ( Example)

6. PILOT MODEL WORK

1. WORK TO CONTINUE IN LINE WITH TODAY’S WORKSHOP

2. 1 HR DAILY AUTO.MAINT ON THE MODEL M/C AREA3. BEFORE AND AFTER PHOTOGRAPHS- A MUST4. PRINTING OF TAGS (WHITE & RED) SUFFICIENT QTY.5. STEPS 1, 2 AND 3 TO BE COMPLETED IN MODEL M/C

AREA6. STEP 3 IS VERY IMPORTANT. CLIT CHECK LIST &

EXTENSIVE VISUAL MANAGEMENT7. MAKE DETAILED ACTION PLAN—MONTH WISE/WEEK

WISE WITH WEIGHTAGE FOR EACH ACTIVITY TO ENABLE MONITORING OF PROGRESS

6. PILOT MODEL WORK

9. PROGRESS BEFORE NEXT VISIT______%10. CROSS AUDIT BY DIFFERENT SUB GROUP11. WHY-WHY ANALYSIS SHEET FOR ALL

MAJOR PROBLEMS12. DISPLAY OF AUTONOMOUS MAINT

ACTIVITIES ON ACTIVITY BOARD13. REGULAR REVIEW MEETINGS BY STEERING

COMMITTEE --AT LEAST ONCE IN A FORTNIGHT( IF MORE IT IS BETTER) IN A STRUSTURED WAY ON FIXED DAYS/DATES AT FIXED TIME & FOR FIXED DURATIONS

7. OPL

• 5 NOS PER PERSON

8. KAIZENES

1. PRODUCTION RELATED - 10 NOS2. MAINT. RELATED - 10 NOS3. QUALITY RELATED - 10 NOS4. AUTO. MAINT. RELATED - 10 NOS5. COST REDUCTION RELATED - 10 NOS

9.REVIEW

METHODOLOGY FOR REVIEW:

a) PRESENTATION BY COMPANY ON PROGRESS OF VARIOUS ACTIVITIES IN MODEL AREA VIS-À-VIS TARGET

b) PRESENTATION ON PROGRESS OF STEP NOS 1 TO 5c) PRESENTATION ON KAIZENd) PRESENTATION ON OPLe) PRESENTATION ON 5S ACTIVITIES2. NEXT VISIT ON.........