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

The 7 Wastes

 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

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 0

M…improvement suggestions up by 10x

pleasant, safe working environment.

become motivated Associates begin to think of TPM as part of their job.

Benefits of TPM

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

Benefits of TPM

TPM

What Does TPM Look Like?

TPM

 Machine Operators are trained to do much of the maintenance operations, and it’s part of their Standard Work

What Does TPM Look Like?

TPM

 Necessary tools are readily available

What Does TPM Look Like?

TPM

 Equipment is modified such that it easy to keep clean, easy

to see when maintenance is required

Befor

e

After

What Does TPM Look Like?

TPM

 Happy and Engaged Associates……

How To Implement TPM?

TPM

1 Formally announce decision to introduce TPM.

2 Conduct TPM introductory education & publicity campaign

3 Create a TPM promotion organization.

Plant Manager Section Managers Group Leaders Shop Floor Associates

Companywide TPM promotion       Committee

     Plant TPM Promotion  Committee 

      Section TPM Promotion      Committee

       PM circles

How To Implement TPM?

TPM

Policy – example:

 Establish a profitable corporate constitution, promote TPM

Establish numerical goals – examples:

 Zero breakdowns,

 Zero defects, seek to maximize overall equipment effectiveness.

4 Establish basic TPM policy and goals.

How To Implement TPM?

TPM

5 Draft a master plan for implementing TPM.

To formulate a master plan for implementation decide what

activities must be pursued to achieve the TPM goals.

The core TPM activities are:

 Focused improvement

 Autonomous Maintenance

 Planned Maintenance

 Education and Training

 Early Equipment Management

 Quality Maintenance

 Administrative and support department activities (Logistics & Office)

6 Kick off TPM initiative – should be designed to cultivate an atmosphere that raises morale and inspires dedication.

9 Build a quality maintenance system.

10 Build an effective administration and support system.

11 Develop a system for managing health, safety, and the

environment.

12 Sustain full TPM implementation and sustain levels.

The first pillars to implement are the Focused Improvem ent, Autonomous Maintenance, Planned Maintenance, & Training and Development

Pillars

How To Implement TPM?

TPM

How To Implement TPM?

TPM

The Eight Major Plant Losses:

 Shutdown loss

 Production adjustment loss

 Equipment failure loss

 Process failure loss

 Normal production loss

 Abnormal production loss

 Quality defect loss

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?

TPM

1 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

2 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

How To Implement TPM?

TPM

3 Defining Machine Operator Tasks

• Develop Standards and Checklists – Cleaning,

Lubrication, Visual Checks, Procedures to keep equipment new

How To Implement TPM?

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 5 Whys

How To Implement TPM?

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

How To Implement TPM?

TPM

How To Implement TPM?

TPM

Benefits of TPM

TPM

 Reactive Maintenance – if it is not broken do 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

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?

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 6 months then monthly for the next 6 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

How to Sustain TPM

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

 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.

Summary

TPM

TPM