Timely and effective startup of new products. Flexible response to the demand trend.Reduction in prices.Highlevel quality assurance. Conservation of resources and energy. Timely and effective startup of new products. Flexible response to the demand trend. Reduction in prices. Highlevel quality assurance. Conservation of resources and energy.
T Total Productive Maintenance P M Zero loss or Zero tolerance for failure through People empowerment © All rights reserved by Gulf Software Consultancy W.L.L INTRODUCTION In the highly competitive world the difference between the winner and the looser is often one hundredth of percentage This requires perfection and zero tolerance for failure leading to Overall Performance Effectiveness better than the competition TOTAL PRODUCTIVE MAINTENANCE AIMS AT:‘Breakthrough improvement in productivity and reducing chronic losses to zero’ ‘Creating a bright, clean, and pleasant factory’ ‘Reinforcing people and facilities and through them, the whole organization’ Addressing ‘Overall equipment effectiveness (OEE)’ Institutionalising ‘Total Employees Involvement’, ‘Participative Management’ and an ‘Overall small group organisation’ Eliminating ‘Inter Departmental Walls’ and facilitating ‘Cross Functional Management’ Being material oriented, it seeks to keep equipment in its intended condition Making possible unmanned operation, factory automation and computer integrated manufacturing “Lean Production” and “Just-In-Time (JIT)“ “Step by Step approach” PILLARS OF TPM PILLARS OF TPM TPM Total Productive Maintenance activities Environment Safety & v Management Ofce TPM Initial Management Upstream Control Training and skill Development Quality Maintenance (hinshitsu-Hozen) Planned Maintenance Focussed Improvement (Kobetsu-Kaizen) Autonomous-Maintenance (Jishu-Hozen) Total Employee Involvement Productive Total Total Productive Maintenance TO MEET TPM BASIC POLICY AND EXAMPLE OF TARGET SETTING MARKET DEMANDS OPERATIONAL DEMANDS • • Timely and effective start-up of new products • Flexible response to the demand trend • Reduction in prices • High-level quality assurance • • Conservation of resources and energy • • • Increase in production and reduction in quality problems Equipment deterioration due to overload operation Elimination of equipment which has design weak points Upgradation of knowledge of equipment control for the operators Improve morale of associates BASIC POLICY Aiming at “Zero accidents”, ”Zero failures”, and “Zero defects” through introduction of TPM with all workers participating, which in turn contributes to the improvement of Overall equipment efficiency and reduction in costs OBJECTIVES • Reduction in equipment failure equipment, tools and jigs • Reduction in waiting and setup time resource conversation and energy saving • Effective use of existing equipment cultivation of manpower Accurate Management of Promotion of Education and training, Benefits of TPM (As seen in various TPM implementation in companies) Tangibles P - Increase in value added productivity by 1.5 - 2.0 times - Improvement in Overall equipment efficiency by 150% to 200% Q - Reduction in defect ratio by 25% - Reduction in customer complaints by 25% C - Reduction in manufacturing cost by 30% Intangibles - JISHU-HOZEN leads to operators maintaining own equipment leading to ownership - Pleasant work environment - Happy visitors to plant leads to business growth D - Reduction in product and work-in-process inventors by half S - Reduction in accidents to zero - Reduction in Pollution cases to zero M - Improvement proposal increased from to 10 Productive Total Total Productive Maintenance STEPS FOR TPM IMPLEMENTATION Top Management declaration of TPM initiative TPM education and awareness Formation of TPM organisation and structure Setting of basic company TPM principles and targets Master plan for TPM implementation Kick-off of TPM company wide Establishing system for improving plant efficiency Establishing upstream control management for new products and equipments Building quality maintenance system 10 Improvement of administration and commercial function 11 Improvement of safety, health, environment system 12 Complete implementation of TPM Total Productive Maintenance TPM – PROCESS MAP Process Focusing Point Responsibility Organisation TPM Declaration Declaration by Top Management about adopting TPM as major initiative for change TPM Awareness Top Management: ½ Day Senior Management : Day Gulf Software ✔ ✔ ✔ Managers/ Executives : Days Formation of TPM Control steering for coordinating company wide activity Organisation Committee Departmental Committee Departmental committee for coordinating with Control committee and department activity Selection of Manager Model Machine (MMM) For department heads and managers to understand & work on a machine for Jishu Start of Jishu Hozen activity in MMM Hozen, OEE and Kobetsu Kaizen activities Target setting Benchmarks and targets for effectiveness of TPM ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ Making Master plan Formal Kick off Implementation & Deployment of TPM activities all over the organisation: Jishu Hozen OEE / Kobetsu Kaizen Planned Maintenance Training & Skill development Office TPM Initial Project Management Safety and Environmental Management Complete implementation of TPM Informing the commitment of Top Management to all, including Partners and Customers to TPM Implement by horizontal deployment Company wide of various TPM activities Regular and continuous training of all people on activity plan Review and monitoring of the activities Corrective action wherever necessary Accessing for results Productive Total Total Productive Maintenance SERVICE OFFERED ON TPM TPM AWARENESS FOR TOP MANAGEMENT ½ Day Purpose To understand TPM philosophy and approach Contents Overview on TPM Steps for implementation Role of Top Management in TPM implementation TPM AWARENESS FOR SENIOR MANAGEMENT Purpose DAY To understand TPM philosophy and approach To understand concept of OEE and its use for management decision making Contents TPM steps OEE Autonomous Maintenance overview Role of Senior management in TPM implementation TPM AWARENESS FOR MANAGERS AND SENIOR EXECUTIVES DAYS Purpose To understand the TPM philosophy and approach for "Zero accidents, Zero failures, and Zero defects", and the various pillars for this goal Contents TPM concepts including details of all pillars Use of OEE for improvement and project identification To understand “Jishu-Hozen” concepts TPM PROJECT IMPLEMENTATION Drawing TPM road-map/master plan for a company Identifying and providing TPM education and training Creation of a model machine Hands on support for making model machine Deployment of all TPM elements company wide TPM project monitoring and review Measurements of benefits planned and achieved TotalProductive Productive Maintenance Total Maintenance About Us ABOUT US Gulf Software and Consultancy is an organisation specialising in the field of TQM Applications We are fast emerging as a center for Knowledge across the Middle East Our wide experience is backed by a highly skilled and totally professional team of consultants who are rated as one of the best in this business today Even though established recently in the year 2005, it is fast emerging as a formidable force to reckon Our team of Consultants have assisted many organizations in their improvement effort for enhancing Business Performance through intervention of different proven tools and techniques of Six Sigma Headquartered at Bahrain, Gulf Software has its spread across the G.C.C countries and presence in select overseas countries as well For Additional Information, please contact: STANDARD PRODUCT DIVISION Gulf Software and Consultancy P.O.Box: 11651, Manama, Kingdom of Bahrain Tel: (+973) 17537833, Fax: ( +973) 17537844, Email: gulfsoftware@yahoo.com T G0309 ISSUE NS For More Information www.gulf software.com © All rights reserved by TQM International Pvt Ltd P