It is a Japanese approach for Creating company culture for maximum efficiency Striving to prevent losses with minimum cost Zero breakdowns and failures, Zero accident, and Zero defects etc The essence of team work (small group activity) focused on condition and performance of facilities to achieve zero loss for improvement Involvement of all people from top management to operator
Courtesy, in part, of Motorola SPS Thank You! WelcomeTo Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information Courtesy, in part, of Motorola SPS Thank You! About T.P.M After World War ll Japanese industries determined that to complete successfully in the world market they had to improve the quality of their products to so, they imported management and manufacturing techniques from United States and adapted them to their circumstances Subsequently, their products became known throughout the world for their superior quality, focusing world attention on Japanese- style management techniques TPM DEVELOPMENT PROGRAM Implementing Total Productive Maintenance Seiichi Nakajima Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information Courtesy, in part, of Motorola SPS Thank You! WHAT IS T.P.M ?? Definition of T.P.M : T.P.M IS: A PRODUCTIVE MANUFACTURING SYSTEM with the TOTAL Participation of: Managers, Supervisors, Engineers, Technicians and Operators T.P.M Includes the Following Benefits: • Maximize Overall Equipment Effectiveness • Establishment a Complete System of Maintenance for the Machine Entire Life • Create a Better Work Environment, Promoting the Participation for All Employees Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information Courtesy, in part, of Motorola SPS Thank You! T.P.M = Medical Science of Equipment PRODUCTION Foton AUTOMATION B-820 VIDEO-AUTO DIE-BONDER MODEL 8030A POWER HEATER Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information Courtesy, in part, of Motorola SPS Thank You! The Main objective of TPM is : Zero Interruptions Zero Defects Zero Accidents Throughout total employees participation from Top Management to Operators, based in the following activities: Autonomous Maintenance • Planned Maintenance • Individual Improvement • Quality Maintenance • Early Equipment Management • Education/Training (People Development) • Safety Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information Courtesy, in part, of Motorola SPS Thank You! PILLARS OF TPM A U T O N O M O U S M A I N T E N A N C E Q U A L I T Y M A I N T E N A N C E P L A N N E D M A I N T E N A N C E I N D I V I D U A L I M P R O V E M E N T T R A I N I N G P E O P L E D E V E L O P S A F E T Y E H S E A R L Y E Q U I P M A N A G E M E N T 5S´s Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information Courtesy, in part, of Motorola SPS Thank You! T.P.M Total Productive Manufacturing People , Equipment and Product Improvement by Working Together EXCELLENCE Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information Courtesy, in part, of Motorola SPS Thank You! PLANT OVERVIEW PLANT OVERVIEW Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information Courtesy, in part, of Motorola SPS Thank You! TPM Self Assessment PLANT OVERVIEW TPM Self Assessment Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information Courtesy, in part, of Motorola SPS Thank You! TPM Self Assessment Background: ∆1991 First attempt to implement TPM ∆ TPM consultant provides training to selected Managers, Supervisors and Engineers ∆ One coordinator with experience in Process and Maintenance is assigned to lead TPM ∆ Literature and materials, prepared and distributed Lack of support and involvement results on failing the implementation Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 10 Courtesy, in part, of Motorola SPS Thank You! T.P.M FOLLOW-UP TEAMS PRESENTATION TEAMS AUDITS TEAMS MEETING TEAMS TEAMS WEEKLY PER PER MONTH MONTH Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information Consultant X MANAGERS VISITS PRESENTATION TWO DAY EVERY TWO MONTHS MONTHLY MEETING 37 Courtesy, in part, of Motorola SPS Thank You! PLANT OVERVIEW TPM Self Assessment Asia Benchmarking Pilot Team Case Study TPM Implementation Expansion Plan Pilot Team Case Study Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 38 Courtesy, in part, of Motorola SPS Thank You! PILOT MACHINE N-62361 Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 39 Courtesy, in part, of Motorola SPS Thank You! Defectives 30 25 20 25 23 23 22 20 20 21 18 19 17 15 10 5 8 6 3 N-662361 JAN 96 JUN Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 FEB JUL N-61162 MAR AUG N-634766 APR SEP TPM Awareness Information MAY OCT 96 40 % T C Courtesy, in part, of Motorola SPS Thank You! 23% 20% 18% 17% SEP AGO JUL JUN MAY ABR MAR 23% 20% OCT./96 20% FEB 25% ENE./96 DOWN TIME 18% 18% 15% 15% 12% N -662361 10% 5% OCT./96 SEP AGO JUL JUN MAY ABR MAR ENE./96 25% FEB % T C 0% 20% 15% N -663242 12% 10% 11% 10% 11% 8% 10% 9% 7% 5% 8% 6% OCT./96 SEP AGO JUL JUN MAY ABR MAR ENE./96 25,00% FEB % T C 0% 20,00% 15,00% N -649666 10,00% 7,50% 5,00% 9% 8% 8% 7% 4% 5% 5% 6% 3% 0,00% Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 41 Courtesy, in part, of Motorola SPS Thank You! 5’S AUTONOMOUS MAINTENANCE Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 42 Courtesy, in part, of Motorola SPS Thank You! INSPECTION IS DETECTION CRASH Broken Part Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 43 Courtesy, in part, of Motorola SPS Thank You! PRESSURE CORRECT INCORRECT TO TO MUCH MUCH PRESSURE PRESSURE CORRECT ALIGNMENT INCORRECT GAUGE Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information NO 44 Courtesy, in part, of Motorola SPS Thank You! CORRECT CENTERING INCORRECT Dummy Part CORRECT SYMMETRY INCORRECT BENT BENT Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 45 Courtesy, in part, of Motorola SPS Thank You! CONTACT CORRECT Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information INCORRECT 46 Courtesy, in part, of Motorola SPS Thank You! One Point Lesson Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 47 Courtesy, in part, of Motorola SPS Thank You! MACHINE PERFORMANCE Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 48 Courtesy, in part, of Motorola SPS Thank You! Defectives 25 23 20 18 “ZERO” 15 May Jun Jul Ago Sep Abr Mar Feb Jan-97 Dec-96 Oct-96 Sep-96 10 Defectives 10 0 0 P.C BOARD DAMAGED % D.T DOWN TIME 15% Sep Aug Jul Jun 20% May Apr Mar Feb Jan-97 Dec-96 18% Nov-96 20% Oct-96 25% 15% 12% 10% 5% 9% 8% 7% 5% 6% 4% 3% 3% 0% Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 49 Courtesy, in part, of Motorola SPS Thank You! WHAT IS NEXT? Big Losses LINK Autonomous Maintenance Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information Planned Maintenance 50 Courtesy, in part, of Motorola SPS Thank You! Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 51 [...]... Courtesy, in part, of Motorola SPS Thank You! PREPARATION / PLANNING STAGE # DEFINE PILOT LINES # AMOUNT OF MACHINES INCLUDED PER LINE # DEFINE CORE TEAM MEMBERS OF EACH LINE # SELECT TEAM MEMBERS PER MACHINE # START ACTIVITIES IN PILOT MACHINES (bottle neck.) Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 22 Courtesy, in part, of Motorola SPS Thank You! Line and Machine... Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 11 Courtesy, in part, of Motorola SPS Thank You! Asia Benchmarking PLANT OVERVIEW TPM Self Assessment Asia Benchmarking Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 12 Courtesy, in part, of Motorola SPS Thank You! TPM Benchmarking Asia Facilities Facility 1 Facility 2 Facility 3 Committee:... Lubrication 7 Training in One Point Lesson Initial Cleaning (Inspection) 8 2 Photos Before Photos After 1 Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 30 Courtesy, in part, of Motorola SPS Thank You! AUTONOMOUS MAINTENANCE 5 Failures Analysis Why´s Analysis 4 Put “F” Tags 6 Actions in Sources of Contamination & Hard access areas Step # 2 3 Find & List Areas of Hard Access... 980810 Autonomous Maintenance Early Equipment Management Planned Maintenance Safety TPM Awareness Information Individual Improvement Training People Development 18 Courtesy, in part, of Motorola SPS Thank You! PROMOTION STRUCTURE (OVERLAPPING SMALL GROUPS) PLANT MANAGER STAFF MANAGERS OPERATIONS TPM PILLARS & PROMOTION OFFICE DEPARTMENT MANAGERS DEPARTMENT SUPERVISORS TPM PROMOTERS TPM TEAM Cayman Systems... 980810 TPM Awareness Information 19 Courtesy, in part, of Motorola SPS Thank You! VISION STATEMENT: TPM PLANT WIDE IMPLEMENTATION Q1 2000 Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 20 Courtesy, in part, of Motorola SPS Thank You! T.P.M IMPLEMENTATION ACTIVITIES MANAGER TEAMS Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 21 Courtesy, ... Focused in just one product line per area Budget assigned for consulting and external training Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 14 Courtesy, in part, of Motorola SPS Thank You! PLANT OVERVIEW TPM Implementation TPM Self Assessment Asia Benchmarking TPM Implementation Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 15 Courtesy, ... Courtesy, in part, of Motorola SPS Thank You! IMPLEMENTATION/CONSULTANT * Q3 1996, Consultant X is selected to be Consultant * Training of Managers, Team leaders and Team members * Master Plan Defined * TPM implementation initiated according to Consultant X recommendations Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 16 Courtesy, in part, of Motorola SPS Thank You!... 980810 TPM Awareness Information 34 Courtesy, in part, of Motorola SPS Thank You! T.P.M DEPLOYMENT L I N E F L O W CURRENT EQUIPMENT IN T.P.M SAME KIND OF EQUIPMENT 1 9 9 8 1997 1999/2000 EXPANSION Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 35 Courtesy, in part, of Motorola SPS Thank You! PROJECTED PROGRESS IN TEAMS Line Wafer Process Line 1 Q-1’ 98 A.M STEP # 1 A.M... Access Sources of Contamination & Hard Access Areas Find & List Sources of Contamination 2 Modify Covers For Easy Visualization & Quick Disassemble 7 Remove “F” Tags Initial Inspection Final Inspection (Audit) 8 1 Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 31 Courtesy, in part, of Motorola SPS Thank You! AUTONOMOUS MAINTENANCE 5 4 Improve time of execution Verify... STEP # 3 MAKING A TENTATIVE CLEANING/ LUBRICATION STANDARD Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 29 Courtesy, in part, of Motorola SPS Thank You! AUTONOMOUS MAINTENANCE 5 Formats: 6 Daily Cleaning & Initial Inspection 4 Hot Spots, CAP-DO 5W´s Develop One Point lesson Major Problems Selection Step # 1 3 Put F Tags Initial Cleaning Standardization Cleaning / Lubrication