Total Productive Maintenance (TPM) by Operational Excellence Consulting

2. © Operational Excellence Consulting. All rights reserved. 2 Learning Objectives • Understand the concept and philosophy of TPM • Learn the 8 pillars of TPM activities and step-by-step implementation approach • Learn the TPM tools and be able to identify and eliminate loss • Learn how to kick-start TPM deployment with Autonomous Maintenance, Planned Maintenance, Focused Improvement, and Education & Training activities to improve equipment effectiveness • Understand the roles of a TPM implementation organization and the critical success factors

3. © Operational Excellence Consulting. All rights reserved. 3 Outline 1. Overview of TPM 2. TPM Foundation: 5S & Visual Management 3. Key Tools for TPM 4. Equipment Loss Analysis & OEE 5. The Eight Pillars of TPM 6. TPM Implementation 7. JIPM TPM Excellence Award Copyrights of all the pictures used in this presentation are held by their respective owners. NOTE: As this is a PREVIEW, only selected slides are shown. To download the complete presentation, please visit: http://www.oeconsulting.com.sg

4. © Operational Excellence Consulting. All rights reserved. 4 Machine failures have many hidden causes Overview of TPM Failure Loosening Contamination CorrosionLeaks FlawsDeformation VibrationCracks Backlash Improper Temperature Wear Less Visible Visible Failure is what we see but is only the tip of the iceberg Minor machine defects are generally unnoticed but are the cause of almost all machine failures

5. © Operational Excellence Consulting. All rights reserved. 5 What is TPM? Total Productive Maintenance (TPM) is a method to achieve maximum equipment effectiveness through employee involvement Management + Operators + Maintenance Overview of TPM

6. © Operational Excellence Consulting. All rights reserved. 6 What TPM Is NOT • A maintenance department program • Just a workshop or event • A way to eliminate skilled trades (maintenance staff, technicians, etc.) • Making operators and office staff into skilled tradesman Overview of TPM

7. © Operational Excellence Consulting. All rights reserved. 7 TPM Principles • Increase Overall Equipment Effectiveness (OEE) • Upgrade operations and maintenance skills • Employee involvement through small group activities • A fact-based approach to continuous improvement Overview of TPM

8. © Operational Excellence Consulting. All rights reserved. 8 Source: Adapted from Toyota Production System TPM Provides Basic Stability for Lean Transformation Stability Heijunka Standardized Work Kaizen Just-In-Time • Continuous flow • Takt time • Pull system • Flexible workforce Jidoka • Separate man & machine work • Abnormality Identification • Poka yoke Goals: highest quality, lowest cost, shortest lead times Involvement Focus of TPM Overview of TPM

9. © Operational Excellence Consulting. All rights reserved. 9 TPM is a Paradigm Shift Overview of TPM Old Attitude TPM Attitude I use I maintain & I fix We maintain Maintenance Operator MaintenanceOperator

10. © Operational Excellence Consulting. All rights reserved. 10 TPM Eliminates/Reduces Waste Over-production Producing more than what the customer needs Inventory Building and storing extra services/products the customer has not ordered Transportation Moving from one place to another Defects Reprocessing, or correcting work Over-processing Adding excess value when the customer does not require it Motion Extra physical/mental motion that doesn’t add value Intellect Not using employees full intellectual contribution Waiting Employees waiting for another process or information Waste Overview of TPM

11. © Operational Excellence Consulting. All rights reserved. 11 Why is TPM Important? • TPM will improve teamwork skills and flexibility between operators and maintenance staff • TPM will improve equipment availability (uptime) • TPM saves us money Overview of TPM

13. © Operational Excellence Consulting. All rights reserved. 13 Eight Pillars (Strategies) of TPM OfficeTPM Safety,Health&Environment AutonomousMaintenance PlannedMaintenance FocusedImprovement EarlyEquipment Management QualityMaintenance Education&Training 5S & Visual Management TPM Goals: Zero Defects, Zero Breakdowns, Zero Accidents Overview of TPM

14. © Operational Excellence Consulting. All rights reserved. 14 TPM Benefits • Increased equipment uptime • Increased plant capacity • Lower maintenance and production costs • Lower defects • Enhanced job satisfaction Overview of TPM

15. © Operational Excellence Consulting. All rights reserved. 15 Sort: Identifying Red-tag Targets Red-tag Targets Types of Items Physical Areas Inventory Equipment Raw materials, procured parts, processing parts, in-process inventory, assembly parts, Semi-finished products, finished products Machines, equipment, jigs, tools, cutting bits, gauges, Measuring instruments, dies, carts, conveyance tools, worktables, cabinets, desks, chairs, supplies Floors, walkways, operation areas, walls, ceilings, lightings, shelves, storage areas, warehouses Source: 5S for Operators, Productivity Press TPM Foundations

16. © Operational Excellence Consulting. All rights reserved. 16 Visual Control - TPM Scorecard TPM Foundations Staff SuggestionsAccidents 1990 1991 1992 1993 0 1 2 3 4 5 Accidents/Year Better '90/9 '91/3 '91/9 '92/3 '92/9 '93/3 '93/9 200 400 600 800 1000 1200 PPM Better 1990 1991 1992 1993 0 20 40 60 80 100 Suggestions/Year Better '90/9 '91/3 '91/9 '92/3 '92/9 '93/3 '93/9 80 85 90 95 Percent, % Better Defect Rate Delivery Performance

17. © Operational Excellence Consulting. All rights reserved. 17 Example – Visual Controls TPM Foundations Source: Society for Maintenance & Reliability Professionals Indicates direction of adjustment Visual controls to improve ease of operations

18. © Operational Excellence Consulting. All rights reserved. 18 Fuguai Tagging (F-Tag) • Fuguai Tags are attached to equipment where problems are discovered • 2 categories of Fuguai Tags:  Blue Tag – repairs by operator  Red Tag – repairs by maintenance staff • Fuguai Register  A log for all Fuguai’s issued and resolved Key TPM Tools

19. © Operational Excellence Consulting. All rights reserved. 19 Types of One-Point Lessons 1. Basic Knowledge Lesson 2. Examples of Problems 3. Examples of Improvement • Training tool designed to fill in knowledge gaps • To ensure team members have consistent knowledge they need for daily production and TPM activities • Lessons are focused on equipment subsystems, safety points, or basic operating information • Based on problems that have already occurred, these lessons are designed to communicate knowledge or skills to help operators prevent similar problems from happening in the future • To ensure that successful improvement ideas are used widely, these lessons present what needs to be done to prevent or correct equipment abnormalities • It describes the approaches, actions, and results of specific improvement projects Key TPM Tools

21. © Operational Excellence Consulting. All rights reserved. 21 Visualizing OEE & the Six Big Losses Plant Not Open Setup & Adjustments Breakdown Minor Stops Reduced Speed Production Rejects Startup Rejects Fully Productive Time Production Not Scheduled PlantOperatingTime Quality Loss FullyProductiveTime Speed Loss NetOperatingTime Downtime Loss OperatingTime Planned Shutdown PlannedProductionTime TotalTime TotalLosses SixMajorLosses Availability Performance Quality X X = OEE Capacity LossesPerfectProduction Source: Adapted from OptimumFX Efficiency OEE/Utilization AssetUtilization Equipment Loss Analysis & OEE

22. © Operational Excellence Consulting. All rights reserved. 22 Equipment Losses & OEE Six Big Losses Downtime Losses Quality Losses Speed Losses Fully Productive Time Net Operating Time Planned Production Time Operating Time Equipment Average total operating loss 30-50% Breakdowns Setups & Adjustments Reduced Speed Minor Stops & Idling Defects & Rework Startup & Yield Loss Breakdowns per machine (stopped longer than 10 mins) – less than once a month Setup/adjustment time – less than 10 mins Achieve ideal cycle times (design speed); increase 15% or more Minor stoppages and idling per machine – under 10 mins Rate (including products to be reworked) – less than 0.1% Startup yield – 99% or more of lot Ideal Cycle Time x Total Pcs Operating Time Good Pieces Total Pieces Operating Time Planned Production Time Availability Quality Performance Greater than 90% Throughput process - Greater than 99% Greater than 95% OEE Factors OEE = Availability x Performance x Quality Source: Adapted from ‘TPM for Supervisors’, Productivity Press Development Team Equipment Loss Analysis & OEE

23. © Operational Excellence Consulting. All rights reserved. 23 Improvement Goals for the 6 Big Losses Type of Loss Goal Explanation 1. Breakdowns 0 Should be zero for all equipment 2. Setups and adjustments minimize As short as possible; less than 10 mins with zero adjustments 3. Reduced speed 0 Should match or – with improvements – exceed equipment specifications 4. Minor stoppages 0 Should be zero for all equipment 5. Defects and rework 0 Extent may vary, but goal should be expressed in parts per million (ppm) 6. Startup loss minimize Equipment Loss Analysis & OEE Source: TPM for Every Operator, Productivity Press Development Team

24. © Operational Excellence Consulting. All rights reserved. 24 Goals of Autonomous Maintenance Goals of Autonomous Maintenance Prevent Equipment Deterioration Equipment Restoration & Proper Management Establish Basic Conditions Autonomous Maintenance

25. © Operational Excellence Consulting. All rights reserved. 25 7 Steps of Autonomous Maintenance 1. Clean and inspect 2. Eliminate problem sources and inaccessible areas 3. Draw up cleaning and lubricating standards 4. Conduct general inspections 5. Conduct autonomous inspections 6. Standardize through visual workplace management 7. Implement autonomous equipment management Source: Autonomous Maintenance for Operators by JIPM Autonomous Maintenance

26. © Operational Excellence Consulting. All rights reserved. 26 Example: General Inspection Abnormal hydraulic pump sound/temperature can mean cavitation, pump failure, etc. Inspection Stickers See something wrong? Smell something? Feel something wrong? Hear something wrong? Source: Nippon Denso Autonomous Maintenance

27. © Operational Excellence Consulting. All rights reserved. 27 Example: Use of Match Marks Match marks are placed on bolts and nuts so that operator can easily detect if bolts have been loosen due to excessive vibrations. These are being placed on critical bolts after each bolt had received their correct torque. Autonomous Maintenance

28. © Operational Excellence Consulting. All rights reserved. 28 Checklist for Daily Operator PM  1. Check coolant level through clear Plexiglas  2. Check heat exchanger fans (strings should be moving)  3. Check servo drive fans (string should be moving)  4. Check heat exchanger air filter (change when dark)  5. Check servo drive air filter (change when dark)  6. Check way lube reservoir (add when low)  7. Check main motor air filter (change when dark)  8. Check main motor cooling fan (string should move)  9. Check mist collector motor and air filter (change when dark)  10. Check bar feeder hydraulic motor air filter  11. Check bar feeder hydraulic oil level (add when low) Example: Checklist for autonomous inspections Autonomous Maintenance

29. © Operational Excellence Consulting. All rights reserved. 29 Maintenance Activities Breakdown Maintenance Predictive Maintenance Preventive Maintenance Routine Maintenance ROBUSTNESS IMPROVEMENT EFFECTIVE AND APPROPRIATE REPAIRS TRENDS MEASUREMENT AND CONTROL CONDITION BASED SERVICING BUILDING OF PROGRAMS TIME BASED APPLICATIONS CLEANING - REFURBISHING LUBRICATION & TIGHTENING DAILY INSPECTION DAILY EQUIPMENT CARE X X X X X X X X X X X Production Maintenance Example: AM – Who does what? Autonomous Maintenance

30. © Operational Excellence Consulting. All rights reserved. 30 Example: Color-coded lubrication container station Source: Nippon Denso Color-coded lubrication container station ensures the right lubricant is applied to the right equipment Autonomous Maintenance

31. © Operational Excellence Consulting. All rights reserved. 31 What is Preventive Maintenance? • Daily maintenance to prevent deterioration • Inspections to measure deterioration • Regular operating checkups • Early treatment to correct the defects of deterioration Planned Maintenance

32. © Operational Excellence Consulting. All rights reserved. 32 Preventive Maintenance is Health Management for Machines Daily prevention Early treatment Prevent Deterioration – through daily maintenance (cleaning, checking, lubrication, adjustment) Restore Deterioration – through preventive repairs before problems occur Health checkups Measure Deterioration – through routine inspections and operating checks Preventive medicine Preventive maintenance Planned Maintenance

33. © Operational Excellence Consulting. All rights reserved. 33 The Four Key TPM Pillars that are Critical for Equipment Reliability Focused Improvement Education & Training Autonomous Maintenance Planned Maintenance Planned Maintenance

34. © Operational Excellence Consulting. All rights reserved. 34 Improving OEE Through Kaizen Event Set TPM Targets Go after the targets with everyone’s help Analyze breakdowns, suggest improvements Track and record performance Achieve and verify targets Report results and have them recognized Focused Improvement Source: TPM Team Guide, Productivity Press Development Team

35. © Operational Excellence Consulting. All rights reserved. 35 Example of TPM implementation structure TPM Responsible (Plant Manager) Focused Improvement Autonomous Maintenance Education & Training Planned Maintenance Safety & Environmental Management Early Equipment Management Office TPM Quality Maintenance TPM Promotion Office TPM Implementation

36. © Operational Excellence Consulting. All rights reserved. 36 12 Steps of TPM Implementation Preparation Kick-off Implementation Announcement to introduce TPM Introductory education campaign for the workforce TPM Promotion (special committees) Establish basic TPM policies and goals Preparation and Formulation of a master plan Develop an equipment management program Develop a planned maintenance program Develop an autonomous maintenance program Increase skills of production and maintenance personnel Perfect TPM implementation and raise TPM levelsStabilization Develop early equipment management program Invite customers, affiliated companies and subcontractors TPM Implementation

37. © Operational Excellence Consulting. All rights reserved. 37 How to Sustain TPM • Engaging employees • Aim for early success • Providing active leadership • Share success stories • Rewards and recognition • Continuously improve OEE • Evolving the TPM initiative over time and integration with Lean Sustaining TPM

39. © Operational Excellence Consulting. All rights reserved. 39 About Operational Excellence Consulting • Operational Excellence Consulting is a management training and consulting firm that assists organizations in improving business performance and effectiveness. • One of our unique strengths is going beyond a tools-focused approach to seamlessly integrate people, processes, technology and continuous improvement initiatives to suit the specific needs and situations of our clients. • We provide corporate learning programs and management advisory services to assist our clients to achieve breakthrough in business performance and effectiveness. Our aim is to support our clients in designing, managing and executing lasting beneficial change.

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