Introduction to lean manufacturing TPM1

What is the TPM ? TPM stands for Total Productive Maintenance. TPM Development was first published in Japan in 1982. Since then new concepts and refinements have been added to the basic program. TPM first took root in the automotive industry. More recently it has been introduced in consumer goods, electronics, plastics and many others. Administrative and support departments such as product development and sales also use TPM. Production output and rate, quality, safety, and the environment depend almost entirely on the state of equipment. TPM is a method for continuously improving the effectiveness of production equipment and processes.

Lorraine Fraser, P.Eng., M.Eng., MBA, CQE, CQA, CQM/OE, CSSBB ASQ Toronto Section – November 11, 2015  Introduction To TPM  Benefits of TPM  What does TPM look like?  How to implement TPM  How to Sustain TPM  Summary  Questions TPM The Wastes TPM       TPM stands for Total Productive Maintenance TPM Development was first published in Japan in 1982 Since then new concepts and refinements have been added to the basic program TPM first took root in the automotive industry More recently it has been introduced in consumer goods, electronics, plastics and many others Administrative and support departments such as product development and sales also use TPM Production output and rate, quality, safety, and the environment depend almost entirely on the state of equipment TPM is a method for continuously improving the effectiveness of production equipment and processes TPM World Class Operating Excellence is Achieved using optimized work standards with group activities of associates who demonstrate ownership Office People Logistics Early Equipment Management Training & Development Productivity Quality Management Cost Environment, Health & Safety Planned Maintenance Quality Autonomous Maintenance Improvement Focused Safety 5S & Teams TPM  Guarantees Significant Tangible Results - Results achieved include – reduction in equipment breakdowns, lower quality defects and claims, higher productivity, shrinking inventory, lower number of accidents P… net productivity up by 2x Q…process defect rate down 90% C…production costs down 30% D…production and work in process inventories halved S…accidents M…improvement suggestions up by 10x  Transforms the Plant Environment – a rusty plant can be reborn as a pleasant, safe working environment  Transforms the Employees - As concrete results are achieved, workers become motivated Associates begin to think of TPM as part of their job TPM Benefits of TPM  Customers and visitors are impressed by these changes  Confidence in the plant’s products increases  Overall Equipment Effectiveness (OEE) is maximized through zero breakdowns and failures, zero accidents, zero defects through total employee involvement  Equipment reliability and maintainability as contributors to quality and productivity is increased  TPM culture promotes zero loss activities  TPM involves all associates from the shop floor to top management TPM Benefits of TPM TPM How To Implement TPM? Select Equipment to work on… • Equipment that is giving you problems with… • Unplanned downtime • Excessive quality problems • Excessive repair costs • Premature “end of life” failures • Running slower than “design” to prevent breakdowns 5S Event… • Improve ability to perform regular inspections • Allow the discovery of potential problems • Log problems and potential problems and develop an immediate action plan • Mark all lubrication, fluid connections and directions, etc • Paint equipment TPM How To Implement TPM? Defining Machine Operator Tasks • Develop Standards and Checklists – Cleaning, Lubrication, Visual Checks, Procedures to keep equipment new 4.  Make Machne Operator maintenance tasks easier/quicker • Easy to see when things need to be maintained • Lubrication needs become obvious to operator • Routine cleaning operations easier • Machine disassembly minimized • Automate maintenance when possible • Clear signals when maintenance is needed • Ensure operator training is complete • Finalize Checklist schedules TPM How To Implement TPM? Define Maintenance Tech Tasks • • • • • Provide Tech support to operator questions Provide clear communication path Spare Parts Program • Equip Manufacturer recommendations • Breakdown History Data Eliminate Equipment Deterioration • Scheduled general inspections • Equipment overhauls triggered by checklists Identify and Resolve Chronic Problems • Breakdown history log • Root cause analysis methods including Whys TPM How To Implement TPM? Define Maintenance Tech Tasks • • • Develop and Analyze Equipment History • Plot failure history • Correlate with Equipment Quality Performance Determine Equipment Parameters That Predict Failure • Use information from equipment manufacturer • Oil, vibration, temperature analysis Develop Equipment Monitoring Systems • Ensure appropriate accuracy and tolerance • Lease equipment to ensure usability before purchase TPM How To Implement TPM? TPM How To Implement TPM? TPM Benefits of TPM  Reactive Maintenance – if it is not broken not fix it  Preventive Maintenance – time or machine cycle based maintenance functions  Predictive Maintenance – functions on feedback that something needs to be done  TPM – Autonomous Maintenance & Planned Maintenance TPM  Loss methologies in use: ◦ Use of a QA Matrix which is a tool that prioritizes actions against the sources of defects in a process The matrix correlates defect modes with machine parameters The matrix identifies the location of ‘Q’ points – the points that need to be controlled to eliminate defects ◦ Defect Reduction Methodology ◦ CpK Improvement Methodology How to Sustain TPM?  Measuring progress is key (through Steering Committee)  The Primary Measurement tool is OEE (Overall Equipment Effectiveness is measures… OEE = Equip Availability X Performance Efficiency X Quality Rate  Build strong teams at every level and staff a promotion office  Track projects weekly from date of closure, up to months then monthly for the next months When a project looses traction, the pillar team analyzes the anomaly & take corrective actions as needed Once a project is sustained for a year, it can be removed from the KPI tracker  Use management indicators that show everyone (at every level) what concrete progress is being made and motivate their continued involvement TPM How to Sustain TPM  Recognized as the Global leaders in TPM  Two audits take place with Japanese auditors  In the face of growing competition, the award drives a continuous culture of improvement the focuses on cost reduction & improvement in efficiencies TPM Summary TPM Summary   TPM is a method for continuously improving the effectiveness of production equipment and processes by improving ‘On Demand’ availability of the equipment, through improved maintenance The primary focus is on involving machine operators in routine maintenance, and making that maintenance easily seen, easily done, and effective This only happens through involvement of every single associate in every department in a factory TPM Questions TPM ... loss TPM How To Implement TPM? TPM How To Implement TPM? TPM How To Implement TPM? TPM How To Implement TPM? TPM How To Implement TPM? | TPM How To Implement TPM? Select Equipment to work on…... 4.  Make Machne Operator maintenance tasks easier/quicker • Easy to see when things need to be maintained • Lubrication needs become obvious to operator • Routine cleaning operations easier • Machine disassembly minimized • Automate maintenance when possible... TPM How To Implement TPM? Defining Machine Operator Tasks • Develop Standards and Checklists – Cleaning, Lubrication, Visual Checks, Procedures to keep equipment new 4.  Make Machne Operator maintenance tasks easier/quicker