Total Productive Maintenance
TPM
Overview
Dave Hoyte, CEO
JL French Corporation
Slide 1
TPM as a Lean Initiative
• Competitive costs require
– Spending control
– Defect control
– Downtime reduction
• TPM = Total Productive Maintenance
– Proactive (with all employees involved)
– Preventive
– Predictive
– Planned
Slide 2
Why Change?
• ACTIONS:
– Reduce defectives / scrap
– Reduction of lost production time
– Lowest possible cost by reducing waste
Slide 3
Lean System
Peak Performance
Pull system / flow production
Rapid Changeover / Customer-driven lot size
Continuous Waste Reduction
Lean Measures
5S
Visual
Factory
TPM
Standardized
Work
Variation reduction / Six Sigma
In-Station Process Control
Leadership by Example & Commitment
Employee Involvement & Mutual Respect
Slide 4
7 Wastes
•
•
•
•
Transportation
Excess production
Added processes
Motion
• Waiting
• Inventory
• Non-conformance (defectives)
Slide 5
Causes of Waste
• Excess Manning
– Poor layout and material presentation
– Rework and extra processes
– Inconsistent / inefficient work methods
• Excess Downtime
–
–
–
–
Tooling condition
Unreliable equipment
Long changeovers
Incapable process
• Defectives - Rework or Replace
– Incapable processes or process not
compatible with customer expectations or
design spec (design for mfg)
– Tooling condition
– Operator methods and errors
Slide 6
Causes of Waste
• Excess Manning
– Poor layout and material presentation
– Rework and extra processes
– Inconsistent / inefficient work methods
• Excess Downtime
–
–
–
–
Tooling condition
Unreliable equipment
Long changeovers
Incapable process
• Defectives - Rework or Replace
– Incapable processes or process not
compatible with customer expectations or
design spec (design for mfg)
– Tooling condition
– Operator methods and errors
Slide 7
Effective TPM Eliminates 5 Losses
1.
2.
3.
4.
5.
Equipment breakdowns
Defects, scrap, and rework
Safety Issues
Mini stoppages
Reduced speed
Slide 8
What is TPM??
TPM is a Lean tool to optimize the effectiveness of
manufacturing equipment and tooling.
1. Starts with 5S / Visual Factory
2. Builds a comprehensive Downtime Database by
cause, frequency, and duration
3. Predicts and prevents downtime by PM system
4. Expands role of Operator as first point of early
warning and prevention
5. Develops Professional Maintenance skills
Slide 9
Operator Autonomous Maintenance
Seven Steps
of TPM
Aut. Mgt.
Standardization
Autonomous Inspection
General Inspection
Initial Standards
Countermeasures for Contamination
Initial Clean-up
77
66
55
44
33
22
11
Slide 10
TPM is Planned, Predictive, & Preventive
1. Starts with 5S / Visual Factory
2. Builds a comprehensive downtime data
base by cause, frequency, and duration
3. Predicts and prevents downtime by PM
system
4. Expands role of Operator as first point of
early warning and prevention
5. Professional Maintenance
Slide 11
5S Workplace
A safe, clean, orderly workplace is
fundamental to quality, efficiency, and teams
Sort (organize)
Shine (clean)
Set in order (make orderly and neat)
Standardize (visual place for everything)
Sustain (maintain the system)
Slide 12
TPM starts with 5S
• You can’t see problems clearly when
the workplace is in disarray
• Cleaning and organizing the workplace
helps the team to uncover problems
• Making problems visible is the first step
of improvement
• Clean machines and workplace create
pride & Safety
Slide 13
Downtime Visual Controls
• Visual or audio alerts
– Abnormality obvious at a glance (e.g. stoppage,
reject, control fault)
– Alerting Maint and team leaders
– Provide real time “scoreboard” for employees
•
•
•
•
•
Machine down light visible from aisle
Production status board (e.g. actual counts vs. goal)
Scrap counts and downtime minutes
Located in clear view in shop (not in control room)
Simple, self regulating, & employee managed
Slide 14
TPM is Planned, Predictive, & Preventive
1. Starts with 5S / Visual Factory
2. Builds a comprehensive
downtime data base by cause,
frequency, and duration
3. Predicts and prevents downtime by PM
system
4. Expands role of Operator as first point of
early warning and prevention
5. Professional Maintenance
Slide 15
Downtime Database
• Categorize at a minimum by Equip, Tooling, C/O, Other
• Segmented bar graph for E-T-O lost time
• Subcategories for Equip (e.g.)
–
–
–
–
Hydraulic / pneumatic
Mechanical / lubrication
Electrical / controls
Shot-end components
• Subcategories for Tooling (e.g.)
–
–
–
–
Slides
Cores
Inserts
Ejector pins
• Subcategories for Other (e.g.)
– Operator error
– Materials
Slide 16
Minimum Downtime Tracking
Downtime by Cause 3500 ton Bay
(avg min/shift per Machine)
Other
Tools
120
100
80
O
Minutes 60
T
40
Equip
E
20
0
1Q02 2Q02
Jun
Jul
Aug
Sep
Oct
Nov
Dec
Slide 17
TPM is Planned, Predictive, & Preventive
1. Starts with 5S / Visual Factory
2. Builds a comprehensive downtime data
base by cause, frequency, and duration
3. Predicts and prevents downtime
by PM system
4. Expands role of Operator as first point of
early warning and prevention
5. Professional Maintenance
Slide 18
Predictive Maintenance Tools
• Rate/hr vs. target or historical normal output (B/W)
• Database
– MP2 / maintenance history
– statistical probability (frequency & duration)
• Physical prediction of impending failure
– Sound (bearing)
– Temperature (cooling water)
– Flash (core pins)
– Shot monitoring system
– SPC on part geometry
– Hydraulic pressure (ejector pins)
– Spindle loads (amps)
– Fluids / Lubrication analysis (milipore)
– Vibration Signature Analysis
Slide 19
Preventive Maintenance System
• History of downtime by major machine & tool
– Downtime measurement & tracking
– Mean Time Between Failures
– Average downtime
– Pareto of causes at component level (eg L/S or temp sensor)
– Cost to maintain
• Develop PM cards based on frequency of failure and magnitude of
average lost time (start small & grow)
– Limit & prox switches
– Shot tip / sleeve
– Critical frame and cylinder mounting bolts
– Expendable tools
– Valves, hoses, packing, seals
• PM’s have instruction, schedule/frequency & sign-off
– PM’s / repairs done in window of opportunity when machine is down
– Cycle count or date based execution of PM’s (eg cutter change)
– PM status visual (work completed / not completed)
Slide 20
TPM is Planned, Predictive, & Preventive
1. Starts with 5S / Visual Factory
2. Builds a comprehensive downtime data base by
cause, frequency, and duration
3. Predicts and prevents downtime by PM system
4. Expands role of Operator as first point
of early warning and prevention
• One point lessons for operator awareness
• Creates OMP (Operator - Maintenance
Partnership)
• Operator performs checks, problem
solving, and improvements
5. Professional Maintenance
Slide 21
TPM
Production Operators
• Clean & Check
• Observe
• Categorize
Production Planning
& Control
• Schedule P.M.
Active
Planned
Maintenance
Process
Quality Engineers
• Standards &
Calibrations
Manufacturing Engineers
• Equipment Planning
• Equipment Studies
Slide 22
OMP - Operator Maintenance Partnership
• Operator training in TPM
TPM
• Operator basic equip inspection
& tooling checks
• Operator basic cleaning
• Operator lubrication check
• One point lessons (capture
knowledge)
• TPM Board & TPM Tags
(proactive operator involvement)
Slide 23
TPM Tag System
• Problem communication tool to and from
maintenance, tool room, and production
– Identify abnormal machine conditions
• Record problem discovered by operator
• Record problem found during scheduled PM
– Status tracking system of requested repairs
– TPM visual management tool (hang tags)
– Repair history for future problem solving
• TPM Tag used for recording problem & fix
– Blue Tag-Operator or Maint responsible to repair
– Red Tag- Safety-related request (priority)
Slide 24
Tag Process
Operator/Supervisor
Production Management
Maintenance
1. Abnormality Identified
2. Fill out Tag Red= Safety
Blue= Prod/Maint
3. Hang C-tag as close to the defect
as possible
4. Hang A &B Tags on the TPM Tag
status board by Machine location and
area of responsibility to correct.
5.Maintenance evaluates problem. If
fixed immediately go to 6. If parts or
time needed, maint pulls A tag from
board. The A tag is MWO. The B
tag is posted on the Maint WO
status section of the TPM Board with
est. timing.
7. Operator/Supervisor check to see
if work was done.
6.After work is completed,
maintenance completes back side of
A tag and places both the A & B tag
in the work completed box
8. If OK, Operator/ supervisor
removes C tag from machine and
places ABC tags in Completed box. If
not OK, tags stay and maint is
contacted. Contact noted on tag.
9. Production management reviews
the information. Also reviews the
comments and takes actions if
required. Places tag in history file box
located in the office
Tag information is recorded and reviewed for continuous improvement of PM
database by Production and Maintenance; Repeat operator tags may indicate
Maint needs to investigate.
Slide 25
TPM is Proactive, Predictive,
Preventive & Planned
1. Starts with 5S / Visual Factory
2. Builds a comprehensive downtime data
base by cause, frequency, and duration
3. Predicts and prevents downtime by PM
system
4. Expands role of Operator as first point
of early warning and prevention
5. Professional Maintenance
Slide 26
Professional Maintenance
•
•
•
•
•
•
•
•
•
Equip Safety
Skill building
Cross-training
Area Maintenance
WC MRO stores
Maint Mgmt System
Down alarms
Radios
Planned PM
Slide 27
Operator Autonomous Maintenance
7 Steps
T P M
Aut. Mgt.
Standardization
Autonomous Inspection
OIL
General Inspection
Prepare Temporary Standards
Countermeasures for Contamination
Initial Clean-up
77
66
55
44
33
22
11
Slide 28
TPM
Initial Focus
5S
TPM I
Step 1
Step 2
Step 3
TPM II
Step 4
Step 5
Step 6
Step 7
prerequisite for TPM I
Slide 29
STEP 3: Prepare Temporary Standards
This step is to enhance the equipment reliability
& maintainability.
• Temporary Check Sheet For Clean-Up,
Lubrication, Start-up, and Shut-down:
–
–
–
–
–
–
What items need to be done
Who will perform the check
How often to check
Where the location is to be checked
What to use for the inspection or cleaning
Target time to complete the task
Slide 30
TPM Summary
• TPM = Total Productive
Maintenance
– Proactive (all employees
involved)
– Preventive
– Predictive
– Planned
• TPM is an integral part
of JLF Total Quality
production System
Peak Performance
Continuous Waste Reduction
5S
Visual
Factory
TPM
Standardized
Work
Slide 31
TPM is a Lean tool for
Quality and
Productivity
Slide 32