Many companies found a reality gap between the hype versus the reality when implementing TPM. Over 21 yrs of TPM consulting for 25 MNCs I found 2 consistent reasons. (1) Failure to understand the Pillar Details and Pillar linkages. (2) Under-estimating TPM resource requirements. Please enjoy this highly condensed presentation. Be enriched and blessed.

1. Understanding Full TPM ImplementationUnderstanding Full TPM ImplementationUnderstanding Full TPM ImplementationUnderstanding Full TPM Implementation
- An Executive Overview- An Executive Overview- An Executive Overview- An Executive Overview (36 slides)(36 slides)(36 slides)(36 slides)
Skype contact moses.tan70 Email mosestc@gmail.com
2017 - ZenPower International, Singapore
Professor, University of Glasgow, UK

2. KEYs In TPM ImplementationKEYs In TPM ImplementationKEYs In TPM ImplementationKEYs In TPM Implementation
(1) TPM Pillar Details & linkages(1) TPM Pillar Details & linkages(1) TPM Pillar Details & linkages(1) TPM Pillar Details & linkages
(2) TPM & the Maintenance Dept. Function(2) TPM & the Maintenance Dept. Function(2) TPM & the Maintenance Dept. Function(2) TPM & the Maintenance Dept. Function
(3) Company Priority / resources(3) Company Priority / resources(3) Company Priority / resources(3) Company Priority / resources
Four Core Pillars
Zero BDs
Zero Defects
Highest OEE / Lowest Product Cost
(Zero-Loss / Ideal Cost)

3. 3
TPM'sTPM'sTPM'sTPM's Three KEY BeliefsThree KEY BeliefsThree KEY BeliefsThree KEY Beliefs
1.1.1.1. Every breakdown and defect is due to aEvery breakdown and defect is due to aEvery breakdown and defect is due to aEvery breakdown and defect is due to a
deviationdeviationdeviationdeviation from the required Basic Machinefrom the required Basic Machinefrom the required Basic Machinefrom the required Basic Machine
ConditionsConditionsConditionsConditions –––– Cleanliness, Lubrication, ProperCleanliness, Lubrication, ProperCleanliness, Lubrication, ProperCleanliness, Lubrication, Proper
Bolting,Bolting,Bolting,Bolting, LifespanLifespanLifespanLifespan Inspection andInspection andInspection andInspection and PartPartPartPart Precision.Precision.Precision.Precision.
2.2.2.2. EEEEveryveryveryvery deviationdeviationdeviationdeviation is due to ais due to ais due to ais due to a Man-Man-Man-Man-MistakeMistakeMistakeMistake andandandand
are preventable byare preventable byare preventable byare preventable by Mistake-proofingMistake-proofingMistake-proofingMistake-proofing (Poka-(Poka-(Poka-(Poka-
Yoke).Yoke).Yoke).Yoke).
3.3.3.3. Manufacturing Excellence is sustained byManufacturing Excellence is sustained byManufacturing Excellence is sustained byManufacturing Excellence is sustained by
building abuilding abuilding abuilding a CICICICI Knowledge BankKnowledge BankKnowledge BankKnowledge Bank totototo revise the PMrevise the PMrevise the PMrevise the PM
shut-down Job-listshut-down Job-listshut-down Job-listshut-down Job-list andandandand sharedsharedsharedshared totototo AM activitiesAM activitiesAM activitiesAM activities....

5. How TPM Pillars Are Linked
5
Planned
Maintenance
( Zero BDs )
Quality
Maintenance
(Zero Defects )
(Poka Yoke)
Autonomous
Maintenance
Pillar (eyes,
ears,hands
helping Maint)
Maintenance Knowledge bankMaintenance Knowledge bankMaintenance Knowledge bankMaintenance Knowledge bank
Focused
Improvement
(100% OEE)
(Cost Reduction)
Enhanced PM
Joblist for
Maintenance
Department

6. 6
TPM End-State GoalsTPM End-State GoalsTPM End-State GoalsTPM End-State Goals
BeforeBeforeBeforeBefore::::
“X” Shut-Down
PM Job-List
After: NewAfter: NewAfter: NewAfter: New
RevisedRevisedRevisedRevised “X”
Shut-Down PM
Job-list.
Autonomous
Maintenance
---- All other Pillars contributionsAll other Pillars contributionsAll other Pillars contributionsAll other Pillars contributions
---- Improved OEE ( BD, DefImproved OEE ( BD, DefImproved OEE ( BD, DefImproved OEE ( BD, Defects.ects.ects.ects.....Jams,Jams,Jams,Jams,
Setup, Speed, Startup andSetup, Speed, Startup andSetup, Speed, Startup andSetup, Speed, Startup and ....Blade-Blade-Blade-Blade-
change losses) .change losses) .change losses) .change losses) .
From AM3: Initial Maintenance Standards (Knowledge-Bank)From AM3: Initial Maintenance Standards (Knowledge-Bank)From AM3: Initial Maintenance Standards (Knowledge-Bank)From AM3: Initial Maintenance Standards (Knowledge-Bank)

7. Model
Machine
Current
PMJob-list
Items
CurrentItems
thatNeed
RevisionofStds
Newitemsto
beaddedto
PMJob-list
CurrentPM
Job-listitems
thatareOK
NEWPMJob-
listitems
(TotalQTY)
AM3final
recommended
list
FPP
Bagging
36items 16 44 20 80items 49items
NPP
Extruder
22items 4 51 18 73items 19items
PM JoblistPM JoblistPM JoblistPM Joblist
(AM3 Status) Sample Only(AM3 Status) Sample Only(AM3 Status) Sample Only(AM3 Status) Sample Only
FMFMFMFM
PacPacPacPac
kkkk
GNDGNDGNDGND
CutCutCutCut

8. 8
AM Step-by-Step Audit Standards
Step # Step Goal Activity Pass-Standard.Step # Step Goal Activity Pass-Standard.Step # Step Goal Activity Pass-Standard.Step # Step Goal Activity Pass-Standard.
Step 0 Prepare F-Tagging Map Grasp the current Machine F-Map (what/where)Step 0 Prepare F-Tagging Map Grasp the current Machine F-Map (what/where)Step 0 Prepare F-Tagging Map Grasp the current Machine F-Map (what/where)Step 0 Prepare F-Tagging Map Grasp the current Machine F-Map (what/where)
Breakdown historyBreakdown historyBreakdown historyBreakdown history
Step-1 Restoration Cleaning & Inspection => 85% repair rateStep-1 Restoration Cleaning & Inspection => 85% repair rateStep-1 Restoration Cleaning & Inspection => 85% repair rateStep-1 Restoration Cleaning & Inspection => 85% repair rate
Step-2a Eliminate Sources of KaiStep-2a Eliminate Sources of KaiStep-2a Eliminate Sources of KaiStep-2a Eliminate Sources of Kai’’’’zen improvements =>70% effective effort tozen improvements =>70% effective effort tozen improvements =>70% effective effort tozen improvements =>70% effective effort to
Contamination reduce Contamination.Contamination reduce Contamination.Contamination reduce Contamination.Contamination reduce Contamination.
Step-2b Improve Equipment KaiStep-2b Improve Equipment KaiStep-2b Improve Equipment KaiStep-2b Improve Equipment Kai’’’’zen improvements =>70% effective effort tozen improvements =>70% effective effort tozen improvements =>70% effective effort tozen improvements =>70% effective effort to
Accessibility improve Accessibility.Accessibility improve Accessibility.Accessibility improve Accessibility.Accessibility improve Accessibility.
Step-3 Initial Maintenance Stds. Equipment-knowledgeable =>50% reduced SuddenStep-3 Initial Maintenance Stds. Equipment-knowledgeable =>50% reduced SuddenStep-3 Initial Maintenance Stds. Equipment-knowledgeable =>50% reduced SuddenStep-3 Initial Maintenance Stds. Equipment-knowledgeable =>50% reduced Sudden
operators.operators.operators.operators. breakdowns.breakdowns.breakdowns.breakdowns.
Step-4 General Inspection Skills General check-up of => 90% reduced SuddenStep-4 General Inspection Skills General check-up of => 90% reduced SuddenStep-4 General Inspection Skills General check-up of => 90% reduced SuddenStep-4 General Inspection Skills General check-up of => 90% reduced Sudden
Training & Implement equipment by operators. breakdowns.Training & Implement equipment by operators. breakdowns.Training & Implement equipment by operators. breakdowns.Training & Implement equipment by operators. breakdowns.
Step-Step-Step-Step-5/5/5/5/6 Autonomous Inspection AM/Pl Maint. responsibility => 95% reduced Sudden6 Autonomous Inspection AM/Pl Maint. responsibility => 95% reduced Sudden6 Autonomous Inspection AM/Pl Maint. responsibility => 95% reduced Sudden6 Autonomous Inspection AM/Pl Maint. responsibility => 95% reduced Sudden
optimized. breakdowns.optimized. breakdowns.optimized. breakdowns.optimized. breakdowns.
Step-7 Organize & manage Self Managing Work TBD.Step-7 Organize & manage Self Managing Work TBD.Step-7 Organize & manage Self Managing Work TBD.Step-7 Organize & manage Self Managing Work TBD.
workplace. Teams.workplace. Teams.workplace. Teams.workplace. Teams.

9. 9
AMAMAMAM0000 - Grasp Curent Status- Grasp Curent Status- Grasp Curent Status- Grasp Curent Status
�Prepared by Maintenance personnel.
� Systematize Defect and Breakdown knowledge in terms
of the 5 Basic Machine Conditions (BMCs)
� TPM believes that zero breakdowns and zero defect can
be achieved if the BMCs ( free of Contamination, correct
lubrication, correct bolting, correct inspection and correct
precision of machine functional parts) are strictly
controlled.
� Provides a starting baseline from which Step AM1
Activities for Continous Improvement is launched.

10. F-Map Find Fuguai - Sample
PlanPlanPlanPlan forforforfor AM1AM1AM1AM1 CleaningCleaningCleaningCleaning &&&& InvestigationInvestigationInvestigationInvestigation MapMapMapMap
(For AM2a,2b - Eliminate Contamination & Improve Accessibility)
Team:Team:Team:Team: LegacyLegacyLegacyLegacy TeamTeamTeamTeam
AssemblyAssemblyAssemblyAssembly #1:#1:#1:#1: InputInputInputInput LoaderLoaderLoaderLoader AssemblyAssemblyAssemblyAssembly BMCsBMCsBMCsBMCs extractedextractedextractedextracted fromfromfromfrom RCARCARCARCA BMCBMCBMCBMC GpGpGpGp ListListListList ofofofof FuguaiFuguaiFuguaiFuguai RestorationRestorationRestorationRestoration ofofofof FuguaiFuguaiFuguaiFuguai
CannotCannotCannotCannot loadloadloadload devicedevicedevicedevice intointointointo expansionexpansionexpansionexpansion tracktracktracktrack
BD1 BD1.BD1.BD1.BD1. CannotCannotCannotCannot loadloadloadload devicedevicedevicedevice intointointointo expansionexpansionexpansionexpansion track.track.track.track.
1a1 Loader stop pin damage. 3a FR None None
1a2 Worn-out expansion track 3c FR None None
1a3 Up/down reflective sensor loose connection. 1 FL None None
1a4 Bolts not properly tight that hold up/down reflective sensor. BR None None
1a5 Bolts not properly tight that hold flag loader position lock pin. BR None None
1a6 Worn-out loader pivot FR None None
1a7 Bolts not properly tight that hold insert loader pivot. BR None None
1a8 Bolts not properly tight that hold wheel singulator drive. BR None None
FuguaiFuguaiFuguaiFuguai discovereddiscovereddiscovereddiscovered duringduringduringduring FFFF----TaggingTaggingTaggingTagging BMCBMCBMCBMC GpGpGpGp
1b11b11b11b1 Bolt 6-32 MissingMissingMissingMissing Completion
1b21b21b21b2 Gasket DamageDamageDamageDamage Replaced
1b31b31b31b3 Lock washer 6-32 MissingMissingMissingMissing Completion
1b41b41b41b4 Insert loader pivot 2b NoneNoneNoneNone None
1b51b51b51b5 bolts 6-32 loader pivot insert WrongWrongWrongWrong screwscrewscrewscrew Replaced
1b61b61b61b6 Pin loader pivot 2a NoneNoneNoneNone None
1b71b71b71b7 Loader base mounting 4b NoneNoneNoneNone None
1b81b81b81b8 Loader base 4a NoneNoneNoneNone None
1b91b91b91b9 Flag loader stop pin 3b NoneNoneNoneNone None
1b101b101b101b10 Loader pivot spring DamageDamageDamageDamage Replaced
1b111b111b111b11 Miniature basic switch DamageDamageDamageDamage terminalterminalterminalterminal supplysupplysupplysupply Replaced
1b121b121b121b12 Button loader pivot wornwornwornworn outoutoutout Replaced
1b131b131b131b13 Spring clamp magazine wornwornwornworn outoutoutout Replaced
Total:Total:Total:Total: 8888 FuguaisFuguaisFuguaisFuguais
AssemblyAssemblyAssemblyAssembly #### 2222 :::: StorageStorageStorageStorage AssemblyAssemblyAssemblyAssembly BMCsBMCsBMCsBMCs extractedextractedextractedextracted fromfromfromfrom RCARCARCARCA BMCBMCBMCBMC GpGpGpGp ListListListList ofofofof FuguaiFuguaiFuguaiFuguai
3a
3c
2b
3b
4a
4b
2a
1
Left
Right
Right
Left
BMC = Basic Machine Conditions

11. 11
( Step-1 : Restoration & Investigation )( Step-1 : Restoration & Investigation )( Step-1 : Restoration & Investigation )( Step-1 : Restoration & Investigation )( Step-1 : Restoration & Investigation )( Step-1 : Restoration & Investigation )( Step-1 : Restoration & Investigation )( Step-1 : Restoration & Investigation )
OPERATORS
LEADER
MAINT.
STAFF
ENGR.
STAFF
CONFIRMATION
OF PROGRESSDEPT.CHIEF
SUPERVISORS
GROUP LEADER
LIST OF EXT/INT
ABNORMALITIES
MEETING TO
PLAN COUNTER
MEASURES
COUNTER
MEASURES
STEP-1 AUDIT
MODEL MACHINE
MAINTENANCE
STAFF
ENGINEERING
STAFF
AUTONOMOUS
MAINTENANCE
GROUP
FOLLOW UP ON AUDIT
FEEDBACK
COUNTERMEASURES
EXTENDED TO ALL
EQUIPMENT
AUDIT
DEPT.CHIEF
LEADER
SUPERVISORS
TO NEXT STEP

12. Find Contam & Access Sample
PlanPlanPlanPlan forforforfor AM1AM1AM1AM1 CleaningCleaningCleaningCleaning &&&& InvestigationInvestigationInvestigationInvestigation MapMapMapMap
(For AM2a,2b - Eliminate Contamination & Improve Accessibility)
Team:Team:Team:Team: BaggingBaggingBaggingBagging Team.Team.Team.Team. Equipment:Equipment:Equipment:Equipment: BaggingBaggingBaggingBagging MCMCMCMC
AssemblyAssemblyAssemblyAssembly #1:#1:#1:#1: BagBagBagBag PickingPickingPickingPicking AssyAssyAssyAssy BMCsBMCsBMCsBMCs extractedextractedextractedextracted fromfromfromfrom RCARCARCARCA DescribeDescribeDescribeDescribe ContaminationContaminationContaminationContamination AccessibilityAccessibilityAccessibilityAccessibility problemsproblemsproblemsproblems
BD1.Bag Picking Assy cannot pick bag Contamination
to the roller printer. 1a3) Cleaning the air filter.
BD#1a - Vac Cup Suction Low * No standing space to remove and
1a1) Suction cup w orn/harden replace filter.
1a2) Suction tubes loose/broke
1a3) Air filter clogged 1a3) Air filter clogged Other BMC Groups
1a4) Pump impeller broke * Water from air suppy IA. 1a4) Pump impeller
1a5) Pump motor burned * Collected on filter elements * Inside assembly cannot see.
1a6) Pump bearing w orn * From Air Compressor. 1a5) Pump motor burned
BD#1b - Vac Cup cannot reach Bags. * Affects a new filter performance * Inside assembly cannot see.
1b1) Cylinder leakage w ithin 2 w eeks. 1a6) Pump bearing w orn
1b2) Solenoid valve jammed * Inside assembly cannot see.
1b3) Air filter clogged
1b4) No w ater trap
HistoricalHistoricalHistoricalHistorical BMCsBMCsBMCsBMCs (not(not(not(not above)above)above)above)
BoltsBoltsBoltsBolts (fuguai/contam/Access)(fuguai/contam/Access)(fuguai/contam/Access)(fuguai/contam/Access)
LubrLubrLubrLubr (fuguai/contam/Access)(fuguai/contam/Access)(fuguai/contam/Access)(fuguai/contam/Access)
Future BD Areas to be investigated: BMCsBMCsBMCsBMCs fromfromfromfrom FuguaiFuguaiFuguaiFuguai FoundFoundFoundFound DescribeDescribeDescribeDescribe ContaminationContaminationContaminationContamination AccessibilityAccessibilityAccessibilityAccessibility problemsproblemsproblemsproblems
Contamination
1) Remove covers of gear assembly Tag 1-FR : Belts w ere w orn and Tag 3-Contam: Dust over elect Tag 3-Contam: Dust over elect
housing and do a clean/tag of the belts, have play. w ires and joints. w ires and joints.
gears and electrical contacts. Tag 2-FR/Lubr : Gear Assy * dust from environment enter * Need to remove 8 screw s
movements noisy through vent gaps over time. to take out covers.
rustand no lubricant.
Tag 3-Contam: Dust over elect
w ires and joints.

13. More Before & After Pictures
13
(Note: Need To Raise Maintenance Work Order For F-Tag Repairs)
Note - An AM1 Provisional Cleaning Std focusses on keeping an eye on the restored fuguais for sustainabilty.

14. 14
( Step-2a : Eliminate Sources Of Contamination )( Step-2a : Eliminate Sources Of Contamination )( Step-2a : Eliminate Sources Of Contamination )( Step-2a : Eliminate Sources Of Contamination )( Step-2a : Eliminate Sources Of Contamination )( Step-2a : Eliminate Sources Of Contamination )( Step-2a : Eliminate Sources Of Contamination )( Step-2a : Eliminate Sources Of Contamination )
Complete Step-1Complete Step-1Complete Step-1Complete Step-1
Step-1 Summary
results & findings
What ?What ?What ?What ?
Where ?Where ?Where ?Where ?
HowHowHowHow
muchmuchmuchmuch
Why ?Why ?Why ?Why ?
AM Team
=> 70%
Countermeasures
1st1st1st1st Pre-
Audit
by TPM
Dept.
Present
Countermeasures
to TPM WC and
implementation
GM/Sponsors
Audit
Step-3Step-3Step-3Step-3
Own area
Buy - Off

15. 5. AM2a Contamination Analysis Worksheet (3/5)5. AM2a Contamination Analysis Worksheet (3/5)5. AM2a Contamination Analysis Worksheet (3/5)5. AM2a Contamination Analysis Worksheet (3/5)AM-2A CONTAMINATIONANALYSISAM-2A CONTAMINATIONANALYSISAM-2A CONTAMINATIONANALYSISAM-2A CONTAMINATIONANALYSIS
MACHINE:MACHINE:MACHINE:MACHINE: ASM5500
QUESTIONSABOUTCONTAMINATIONSOURCEQUESTIONSABOUTCONTAMINATIONSOURCEQUESTIONSABOUTCONTAMINATIONSOURCEQUESTIONSABOUTCONTAMINATIONSOURCE
DURINGINVESTIGATIONSDURINGINVESTIGATIONSDURINGINVESTIGATIONSDURINGINVESTIGATIONS
ACTUALFACTSCOLLECTEDACTUALFACTSCOLLECTEDACTUALFACTSCOLLECTEDACTUALFACTSCOLLECTED SKETCHTHECONTAMINATIONFALL-PATHSKETCHTHECONTAMINATIONFALL-PATHSKETCHTHECONTAMINATIONFALL-PATHSKETCHTHECONTAMINATIONFALL-PATH
MACHINESECTION:MACHINESECTION:MACHINESECTION:MACHINESECTION: Waferhandler-Port1 1111Whatisit?Whatisit?Whatisit?Whatisit? BrokensiliconpiecesBrokensiliconpiecesBrokensiliconpiecesBrokensiliconpieces
2222Whereisthesource?Whereisthesource?Whereisthesource?Whereisthesource? Waferprotrudingfrom Port1Elevatorcassette
3333How thecontaminationgotthere?(TheFall-Path)How thecontaminationgotthere?(TheFall-Path)How thecontaminationgotthere?(TheFall-Path)How thecontaminationgotthere?(TheFall-Path) Notfullyinsertedbecausecassettewasnotseated
properlythensmashedagainstlidhousingupon
portinitialise
CONTAMINATIONTYPE:CONTAMINATIONTYPE:CONTAMINATIONTYPE:CONTAMINATIONTYPE: Brokenwafer 4444Whyisthecontaminationthere?Whyisthecontaminationthere?Whyisthecontaminationthere?Whyisthecontaminationthere? Wafernotfullyinserted
5555Whenitgetthere?Whenitgetthere?Whenitgetthere?Whenitgetthere? Uponimpactwithundersideoflidhousing
REFERENCE#:REFERENCE#:REFERENCE#:REFERENCE#: CONTAMINATIONBASELINECONTAMINATIONBASELINECONTAMINATIONBASELINECONTAMINATIONBASELINE BASELINEMEASUREMENTBASELINEMEASUREMENTBASELINEMEASUREMENTBASELINEMEASUREMENT
a)a)a)a)HOW MUCH?(volume,weight,countoranactualHOW MUCH?(volume,weight,countoranactualHOW MUCH?(volume,weight,countoranactualHOW MUCH?(volume,weight,countoranactual
sample)sample)sample)sample)
1brokenwaferon5areasindicated
CONTAMINATIONEFFECT:CONTAMINATIONEFFECT:CONTAMINATIONEFFECT:CONTAMINATIONEFFECT:
b)b)b)b)HOW LONG?-(RecordthetimefortheQtyofHOW LONG?-(RecordthetimefortheQtyofHOW LONG?-(RecordthetimefortheQtyofHOW LONG?-(RecordthetimefortheQtyof
contaminationtoaccumulate)contaminationtoaccumulate)contaminationtoaccumulate)contaminationtoaccumulate)
6Months
BreakdownBreakdownBreakdownBreakdown
DefectDefectDefectDefect
ContaminateLubricationContaminateLubricationContaminateLubricationContaminateLubrication
xxxx GeneralAreacontaminationGeneralAreacontaminationGeneralAreacontaminationGeneralAreacontamination

16. 7. JH AM2a Audit Standards & Results.7. JH AM2a Audit Standards & Results.7. JH AM2a Audit Standards & Results.7. JH AM2a Audit Standards & Results.AREAAREAAREAAREA ELEMENTSELEMENTSELEMENTSELEMENTS MAXMAXMAXMAX POORPOORPOORPOOR GOODGOODGOODGOOD EXCELLENTEXCELLENTEXCELLENTEXCELLENT PTSPTSPTSPTS COMMENTS FOR SCORECOMMENTS FOR SCORECOMMENTS FOR SCORECOMMENTS FOR SCORE
BELOW MAXIMUMBELOW MAXIMUMBELOW MAXIMUMBELOW MAXIMUM
1. Is the level of cleaning
inspection started in Step 1
maintained as a regular part
of the activities?
10101010
Evidence of
ineffective cleaning &
inspection
0000----3333
Reasonable
implementation but
can do better
4444----7777
Excellent adherence
and embedded as part
of process
8888----10101010
10
2. Is there evidence of training
and development of
members (visual controls,
equipment functions, and
tools)?
15151515
Little evidence of skill
enhancement
0000----5555
Majority are
demonstrating
significant skills
6666----10101010
High levels of skill
evident in the nos. of
OPL’s and training
11111111----15151515 15
SKILLUPGRADINGSKILLUPGRADINGSKILLUPGRADINGSKILLUPGRADING
3. Are all participating in
activities (attendance list)? Is
MA able to explain activities
& m/c functions? Is Team
Leader coordinating
activities?
10101010
Low attendance
(<80%) and skill
development or
coordination
0000----3333
Some activity but
inadequate
development and
attendance at <80%
4444----7777
High levels of
participation (>80%)
and MA are able to
explain
8888----10101010 10
4. Are sources of contamination
summarized into a list,
thoroughly analyzed and
effective countermeasures
implemented?
15151515
Some information but
disorganized
0000----5555
Some activity but
generally inadequate
6666----10101010
High levels of activity
and progress
11111111----15151515 13
Need to add latest Breakdowns and
chronic defects in the Gap Analysis to
find more sources of Contamination.
EQUIPMENTSTAEQUIPMENTSTAEQUIPMENTSTAEQUIPMENTSTATUSTUSTUSTUS
5. Are the losses caused by
contamination quantified and
counter-measures to reduce
contamination by >70%
effective?
15151515
A vague idea of
losses, and not
quantified
0000----5555
Some activity in place
but improvement to
reduce contamination
is < 70%
6666----10101010
Very progressive, with
clear goals and results
are >70% reduction of
contamination.
11111111----15151515 15
6. Have maintenance tasks
been identified for transfer to
operators? Is there a plan to
upgrade skills?
5555
Few if any
0000----2222
Some activities are in
place but no plans
3333----4444
Skill levels are clear
and transfer plans in
place
5555 5
IMPROVEMENTIMPROVEMENTIMPROVEMENTIMPROVEMENT
SSSS
7. Are the majority of “efu”
closed or planned for
closure?
5555
Most “efu” are still
pending
0000----2222
Clear progress made
on “efu” elimination
3333----4444
Most “efu” are closed
or with action plan
5555 5
POTENTIAL SCOREPOTENTIAL SCOREPOTENTIAL SCOREPOTENTIAL SCORE 75757575 ACTUAL SCOREACTUAL SCOREACTUAL SCOREACTUAL SCORE 73737373 Overall =Overall =Overall =Overall = 96.5%96.5%96.5%96.5%
AM2a Audit Standards (JIPM-Compliant)AM2a Audit Standards (JIPM-Compliant)AM2a Audit Standards (JIPM-Compliant)AM2a Audit Standards (JIPM-Compliant)

17. 17
AMAMAMAM2a2a2a2a Benefit:Benefit:Benefit:Benefit:
� AM2a focus against the sources of
contamination and achieves => 70%
reduction of the contamination baseline.
� By reducing Contamination we reduce
machine breakdowns and product defects
and makes the machine and workplace
cleaner.

18. 18
( Step 2b : Improve Equip Accessibility To Maintain ).( Step 2b : Improve Equip Accessibility To Maintain ).( Step 2b : Improve Equip Accessibility To Maintain ).( Step 2b : Improve Equip Accessibility To Maintain ).
AM LeaderAM LeaderAM LeaderAM Leader
Model m/cModel m/cModel m/cModel m/c
PassedPassedPassedPassed
Step 2Step 2Step 2Step 2
Areas difficult orAreas difficult orAreas difficult orAreas difficult or
inaccessible for cleaninginaccessible for cleaninginaccessible for cleaninginaccessible for cleaning
checking & lubricatingchecking & lubricatingchecking & lubricatingchecking & lubricating
InaccessibleInaccessibleInaccessibleInaccessible
No Place ToNo Place ToNo Place ToNo Place To
StandStandStandStand
Wiring or pipingWiring or pipingWiring or pipingWiring or piping
obstructobstructobstructobstruct
Cannot seeCannot seeCannot seeCannot see
easilyeasilyeasilyeasily
Time ConsumingTime ConsumingTime ConsumingTime Consuming
to cleanto cleanto cleanto clean
Time ConsumingTime ConsumingTime ConsumingTime Consuming
to cleanto cleanto cleanto clean
Product ManagerProduct ManagerProduct ManagerProduct Manager
Operator Leader/ OperatorsOperator Leader/ OperatorsOperator Leader/ OperatorsOperator Leader/ Operators
SupervisorSupervisorSupervisorSupervisor
Model MachineModel MachineModel MachineModel Machine
Goes ToGoes ToGoes ToGoes To
Step 4Step 4Step 4Step 4
Pre-AuditPre-AuditPre-AuditPre-Audit
by TPM Deptby TPM Deptby TPM Deptby TPM Dept....
W/CW/CW/CW/C
Buy OffBuy OffBuy OffBuy Off
GMGMGMGM
AuditAuditAuditAudit
OwnOwnOwnOwn
AreaAreaAreaArea
Buy OffBuy OffBuy OffBuy Off

19. 19
AMAMAMAM2b2b2b2b Benefit:Benefit:Benefit:Benefit:
� Many maintenance items are Time-
consuming and/or Hard-to-Access for
Cleaning, Lubrication, Bolting,
Inspection and Precision Checks.
� AM2b reduces accessibility time
by => 70% of the baseline time.

20. 20
AM3 Benefit:AM3 Benefit:AM3 Benefit:AM3 Benefit:
�Based on "total fuguai" data, revise &
Improve and expand the PM Job-list
�Operators become all-present Eyes,
Ears, Hands For the accessible Sub-
set of updated PM Job-list for Cleaning,
inspection & precision checks.

21. Model
Machine
Current
PMJob-list
Items
CurrentItems
thatNeed
RevisionofStds
Newitemsto
beaddedto
PMJob-list
CurrentPM
Job-listitems
thatareOK
NEWPMJob-
listitems
(TotalQTY)
AM3final
recommended
list
FPP
Bagging
36items 16 44 20 80items 49items
NPP
Extruder
22items 4 51 18 73items 19items
PM JoblistPM JoblistPM JoblistPM Joblist
(AM3 Status) Sample Only(AM3 Status) Sample Only(AM3 Status) Sample Only(AM3 Status) Sample Only

22. 22
Continuous Improvement W orksheet For Updating PM Standards Job-list ItemsContinuous Improvement W orksheet For Updating PM Standards Job-list ItemsContinuous Improvement W orksheet For Updating PM Standards Job-list ItemsContinuous Improvement W orksheet For Updating PM Standards Job-list Items
Toolset Name:Toolset Name:Toolset Name:Toolset Name:
BD #1 Tubes jamBD #1 Tubes jamBD #1 Tubes jamBD #1 Tubes jam
M 70SW11 u/s v Add
blocked drive v v Revise
Degraded proxim ity
switch v Add
battery valve u/s v Add
rot.drive jam , v NC
AM 2 C-measures
access panel Add
W orn earth wire v Add
BD #2 Tubes cantBD #2 Tubes cantBD #2 Tubes cantBD #2 Tubes cant
shiftshiftshiftshift
rot.drive jam , v Add
proxim ity switch
worn v Add
tube tower dirty v v Revise
cylinder leak v Add
singulator fingers
loose v Add
tube stack height
loosen v Add
Tubes are not moving one
by one smoothly and some
jammin g are occuring.
Tubes are not able to be
shifted one by one
smoothly to the Loader
Gripper.
New Fuguai Observed during Tagging…New Fuguai Observed during Tagging…New Fuguai Observed during Tagging…New Fuguai Observed during Tagging… ....
1. Base Unit1. Base Unit1. Base Unit1. Base Unit
Loader.Loader.Loader.Loader.
Assy 1-1)
Loader Input
stack
To hold the
tubes of
devices
while
waiting to
be loaded
into the
machine
Assy 1-2
Loader Tube
shifter
PM itemsPM itemsPM itemsPM items
DecisionDecisionDecisionDecision
a) no change b)
revise stds c) add
to PM list
Information sourceInformation sourceInformation sourceInformation source
(BD/Def/Fuguai/)(BD/Def/Fuguai/)(BD/Def/Fuguai/)(BD/Def/Fuguai/)
2) PM2) PM2) PM2) PM
Job-listJob-listJob-listJob-list
System ID -System ID -System ID -System ID -
Drive/Elect/Pnue/Hd
y/Water…………........
AssyAssyAssyAssy
overalloveralloveralloverall
functionfunctionfunctionfunction
Early Warning SignsEarly Warning SignsEarly Warning SignsEarly Warning Signs
(M C or Product)(M C or Product)(M C or Product)(M C or Product)
M aint PartsM aint PartsM aint PartsM aint Parts
Repaired/ ReplacedRepaired/ ReplacedRepaired/ ReplacedRepaired/ Replaced

23. AM Operators becomes Maintenance DeptAM Operators becomes Maintenance DeptAM Operators becomes Maintenance DeptAM Operators becomes Maintenance Dept’’’’s extras extras extras extra ““““ears,ears,ears,ears,
eyes, hands, noseeyes, hands, noseeyes, hands, noseeyes, hands, nose”””” to detect early signs of MC trouble andto detect early signs of MC trouble andto detect early signs of MC trouble andto detect early signs of MC trouble and
thus helped to change Un-Planned Events into Plannedthus helped to change Un-Planned Events into Plannedthus helped to change Un-Planned Events into Plannedthus helped to change Un-Planned Events into Planned
Events (Planned Maintenance)Events (Planned Maintenance)Events (Planned Maintenance)Events (Planned Maintenance)

24. 24
AM4 Benefit:AM4 Benefit:AM4 Benefit:AM4 Benefit:
� Further improve/expand the PM
Joblist from successful OEE big losses
projects.
� Operators' scope increased, some
experienced operators can do line
maintenance.

25. M-Q (Machine-Quality) Summary after solving
"Thickness Fails" chronic defect.
Copper Brush, Flipper Spring
and Brass Bar.
Plating Chemical
Dryer Heater
Corner Spray and Rinsing Water
Dryer Blower
Part of MachinePart of MachinePart of MachinePart of Machine Plating ChemicalPlating ChemicalPlating ChemicalPlating Chemical FlipperFlipperFlipperFlipper B. Bar / C. BrushB. Bar / C. BrushB. Bar / C. BrushB. Bar / C. Brush Dryer HeaterDryer HeaterDryer HeaterDryer Heater
Measurement Chemical Content Tension Contact Pressure Hot Air Temperature
Std. Value MSA: 37.5% +/- 5% Upper <= 250 g Upper = 6 kg/cm Upper = 130 deg. C
TIN: 37.5 g/l +/- 5 g/l Nominal = 120g Nominal = 5.5 kg/cm Nominal = 125 deg C
Additive: 2 g/l +/- 0.5 g/l Lower => 60g Lower = 5 kg/cm Lower => 120 deg C
Interval Daily Weekly Forthnightly Daily
Quality DefectQuality DefectQuality DefectQuality Defect
Thickness FailThickness FailThickness FailThickness Fail Thickness FailThickness FailThickness FailThickness Fail Thickness FailThickness FailThickness FailThickness Fail Thickness FailThickness FailThickness FailThickness Fail
Quality of M/c PartQuality of M/c PartQuality of M/c PartQuality of M/c Part
Circularity
Content ����
O O O
Deterioration
Smoothness
9999 10101010 11111111 12121212 13131313
111122223333
44445555
66667777
8888
14141414

26. Checked by Prepared by Phenomenon Physical view (Logical reasoning)
PM Analysis Chart No 3/5
Illegible or partial marking occurs during the marking
process at TM06.
The rubber pad does not transfer all the full characters from the stamp plate
to the package surface resulting in Illegible Marking
Contributing Condition Investigation Result 4 M Correlation,
First Item
Investigation Result
4M Correlation,
Second Item Investigation/ Investigation Result If NG, Countermeasure Result
Investigation Measuring
Method
Temporary
Decision
Criterion
Measure -
ment Value
Decision
Investigation/ Measuring
Method
Temporary
Decision Criterion
Measure -
ment Value
Decision
(3rd, 4th, 5th and 6th
Items
Measuring
Method
Temporary
Decision
Criterion
Measure -
ment Value
Decision why NG?
Restoration, Replace -
ment, Improvement,
Remodeling
Measurement
Value
Decision
3. INCOMPLETE
OR INSUFFICIENT
DEPTH OF 9 - 11 mils 7 mils NG 3.1 Deterioration 0.49 W - 0.46 W NG 0.50 W OK
CHARACTERS of laser Engraver 0.52W
ON STAMP PLATES. beam power
SIDESIDESIDESIDEVIEWVIEWVIEWVIEW OFOFOFOF PLATEPLATEPLATEPLATE
SIDESIDESIDESIDEVIEWVIEWVIEWVIEW OFOFOFOF PLATEPLATEPLATEPLATE Laser after power
deterioration
Actual
Laser
Characters not been
engraved deeply
caused illegible
marking. Characters not been
engraved deeply
caused illegible
marking.
2. Uneven stamp Even layer No method NG
plate layer. to measure
3. Residue ink on No ink residue Have ink NG 1. Not fully 1. To immerge 60 to 65 mm OK
used plate. in characters residue immerged in Stamp Plate into 75 mm
or stamp plate acetone after use. acetone properly.
2. Delayed to 2. Immediately maximum 15 min OK
immerge stamp immerge the plate 30 min
in acetone. after use. after
3. Stamp plate used
not cleaned
properly.
4. Acetone 4. To change the No No OK
container dirty. acetone 2x per week Illegible Illegible
marking. marking.

27. Design of Experiments During P-M Analysis ForDesign of Experiments During P-M Analysis ForDesign of Experiments During P-M Analysis ForDesign of Experiments During P-M Analysis For
Chronic DefectsChronic DefectsChronic DefectsChronic Defects

29. OEE = Availability x Performance Rate x Quality Rate

30. OEE Waterfall Chart
Single-Dimensional chart (Less Useful)
1. Speed Loss
2. MTBA & Idling

31. OEE Loss Analysis Chart
Quantity Vs Time 2-D Chart (More Useful)
Speed Loss
(Company gap)
MTBA&Idling
Quality Loss
Speed Loss
(World class gap)
Availability
Loss

32. Source: JIPM 2014 Criteria.
frequently Process Improvements takes several
months during which unpredictable changes
in energy, materials, overhead costs, new process
problems. etc offset or hide the real cost reductions
achieve by them causing possible loss of motivation
Visit www.leantargetcosting for a software solution.

33. Using Costs To Drive C.I. Activities
Software uses Toyota Principles, TPM OEE, Lean 6S.
Watch on Youtube, Youku, Vimeo
https://www.youtube.com/watch?v=A-YG7K-E-d0
Watch on Youtube, Youku , Vimeo
https://www.youtube.com/watch?v=c-
sqDNGmSGk&t=10s
Principles of measuring ROI of Lean 6S
and TPM OEE Projects - 1min 45s
How to plan X% Product Cost Reduction
& link to CI, TPM, Lean 6S - 2min 46s

34. Notes:
1. The Process Yield Project can reduce the Process Cost by 9.21% (Rank 1 ticked)

35. Note: Red numbers are Cost-Reductions adjusted to Baseline conditions to eliminate noise.

36. 36