Total Productive Maintenancelssbasics.com/wp-content/uploads/2015/04/TPM-K2.pdf · Total Productive Maintenance (TPM) Roadmap Six Steps to TPM Clean machine thoroughly Eliminate and
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Total Productive Maintenance
What is TPM?
A process used to completely eliminate unplanned downtime in the manufacturing process; thus, improving the predictability of the manufacturing process, quality, delivery and cost.
Why do TPM?
Our goal is to create flow
Lost time interrupts flow
TPM eliminates wasted time due to machines’ downtime
Total Productive Maintenance (TPM)
Roadmap
Six Steps to TPM
Clean machine thoroughly
Eliminate and fix obvious problems
Use 5 Why’s to evaluate and fix the root causes of dirt
Agree on basic productive maintenance
As a team, perform basic productive maintenance and establish standard work for the process
Implement 5S in area surrounding the machine
Integrate this standard work into the cell’s standard work
Step 1 - Clean Machine Thoroughly Beginning:
Step 1 - Clean Machine Thoroughly Beginning:
Step 2 - Eliminate & Fix Problems - Red Tag Locations -
Step 2 - Eliminate & Fix Problems - Red Tag Locations -
Step 2 - Eliminate & Fix Problems - Red Tag Locations -
Results After Step 1 & 2
Results (After Step 1 & 2, pictures) :
Results (After Step 1 & 2) :
Results (After Step 1 & 2) :
Results (After Step 1 & 2) :
> 95% of oil leaks stopped (else waiting on
parts/service)
Savings: leakage of 1, 55 gallon drum of oil every
1-2 weeks (approx $8190.00 per year.)
Savings: Man-hours, clean-up materials, waste
material (approx $37000.00 per year.)
Operator to concentrate on production rather than
unplanned clean-up.
Create a weekly “Monitor & Lubrication” check sheet
Create a means to easily locate the specific location on machine
Provide pictorials and instructions, include:
Description of area
Type of lubricant to be used
Volume of lubricant to be used
Situation to perform operation
Step 3 - Agree on basic TPM (Overview)
CheckDaily check of oil level, air leaks and
oil leaks
CheckWeekly check edge liner fluid level
and filters
Spray UNWIND AND REWIND OP SIDE
SprayUNWIND AND REWIND DRIVE
SIDE
Spray PRINT STATIONS OP SIDE
Spray PRINT STATIONS DRIVE SIDE
Lube UNWIND AND REWIND OP SIDE
LubeUNWIND AND REWIND DRIVE
SIDE
Lube PRINT STATIONS OP SIDE
Lube PRINT STATIONS DRIVE SIDE
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TPM Checklist
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Step 4 of 6 – Establish Basic TPM
(Team Based)
Drive Side Unwind/Rewind Section Lube
Locations
1
2
3
4
5
6
7
8
9
16
Top Chill Roller - Drive side
2 pumps of XYZ Grease
Lube while machine is Down
1 2
#2 Chill Roller - Drive side
2 pumps of XYZ Grease
Lube while machine is Down
Drive Side Unwind/Rewind Section Lube
Instructions
Drive Side Unwind/Rewind Section Lube
Instructions
Chill roll driver - Drive side
2 pumps of XYZ Grease
Lube while machine is UP
Rewind shaft - Drive side
2 pumps of XYZ Grease
Lube while machine is UP
3 4
SUN MON TUES WED THURS FRI SAT NUMBER CAUSE
DATE 31 1 2 3 4 5 6 1 ANILOX ROLLERS CLUTCH
CAUSE NO. 2 ANILOX ROLLERS TEETH
START
DOWNTIME3 DRIVE SYSTEM FOR ANILOX
END
DOWNTIME4 FRONT END HYD. (ARM LIFTS)
TOTAL
DOWNTIME5 BACK END HYD. (ORBIT MOTOR)
REPAIR TIME 6 BRAKE SYSTEM
REPAIRED
BY7 TENSION CONTROLLER
DATE 7 8 9 10 11 12 13 8 AIR SHAFTS
CAUSE NO. 9 CONTROL PANEL (ELECT)
START
DOWNTIME10 ADVANCE RETARD MOTORS
END
DOWNTIME11 IDLER/PATH ROLLER
TOTAL
DOWNTIME12 AIR SYSTEMS
REPAIR TIME 13 MISC ELECTRIC
REPAIRED
BY14 MISC HYDRAULIC
DATE 14 15 16 17 18 19 20 15 *OTHER (DEFINE AT BOTTOM)
CAUSE NO.
START
DOWNTIME
END
DOWNTIME
TOTAL
DOWNTIME
REPAIR TIME
REPAIRED
BY
DATE 21 22 23 24 25 26 27
CAUSE NO.
START
DOWNTIME
END
DOWNTIME
TOTAL
DOWNTIME
REPAIR TIME
REPAIRED
BY
DEFINE OTHER:
YEAR 2007JANUARY
KIDDER 2 MAINTENANCE RELATED UNPLANNED DOWNTIME
MONTHLY DOWNTIME CALENDAR
Step 6 of 6 – Integrate TPM
DOWNTIME VS REPAIR TIME(12 MONTH PERIOD)
0
5
10
15
20
25
30
35
40
45
ANIL
OX R
OLL
ERS C
LUTC
H
ANIL
OX R
OLL
ERS T
EETH
DRIV
E SYSTEM
FO
R A
NIL
OX
FRO
NT E
ND H
YD. (AR
M L
IFTS)
BACK E
ND H
YD. (O
RBIT M
OTO
R)
BRAKE S
YSTEM
TENSIO
N C
ONTR
OLL
ER
AIR S
HAFTS
CO
NTROL
PANEL (ELE
CT)
ADVAN
CE RETARD
MO
TORS
IDLE
R/P
ATH RO
LLER
AIR S
YSTEMS
MIS
C E
LECTR
IC
MIS
C H
YDRAU
LIC
*OTH
ER (DEFIN
E AT B
OTTO
M)
CAUSE OF DOWNTIME
HO
UR
S
TIME DOWN
REPAIR TIME
Step 6 – Integrate TPM
5
2
4
7
1
3
0
1
2
3
4
5
6
7
8
NU
MB
ER
OF
OC
CU
RA
NC
ES
CAUSE OF DOWNTIME
DOWNTIME OCCURANCES(12 MONTH PERIOD)
Step 6 – Integrate TPM
Step 6 – Integrate TPM
Proposed Visual Location:
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