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TPM, OEE, Total Productive TPM, OEE, Total Productive TPM, OEE, Total Productive TPM, OEE, Total Productive Maintenance Implementation.Maintenance Implementation.Maintenance Implementation.Maintenance Implementation.
Why Lots of Companies Fail During TPM Execution (36 slides)Why Lots of Companies Fail During TPM Execution (36 slides)Why Lots of Companies Fail During TPM Execution (36 slides)Why Lots of Companies Fail During TPM Execution (36 slides)
Companies Fail in TPM Execution Companies Fail in TPM Execution Companies Fail in TPM Execution Companies Fail in TPM Execution When They Not Clear About... When They Not Clear About... When They Not Clear About... When They Not Clear About...
(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
Companies Fail when They don't Companies Fail when They don't Companies Fail when They don't Companies Fail when They don't . . . . Understand TPM's Understand TPM's Understand TPM's Understand TPM's Three KEY Three KEY Three KEY Three KEY . . . . BeliefsBeliefsBeliefsBeliefs1.1.1.1. Every breakdown and defect is due to a Every breakdown and defect is due to a Every breakdown and defect is due to a Every breakdown and defect is due to a deviationdeviationdeviationdeviation . . . . from the required Basic Machine Conditions from the required Basic Machine Conditions from the required Basic Machine Conditions from the required Basic Machine Conditions –––– . . . . Cleanliness, Lubrication, Proper Bolting, Cleanliness, Lubrication, Proper Bolting, Cleanliness, Lubrication, Proper Bolting, Cleanliness, Lubrication, Proper Bolting, Lifespan Lifespan Lifespan Lifespan . . . . Inspection and Inspection and Inspection and Inspection and Part Part Part Part Precision.Precision.Precision.Precision.
2.2.2.2. EEEEvery very very very deviationdeviationdeviationdeviation is due to a is due to a is due to a is due to a Man-Man-Man-Man-MistakeMistakeMistakeMistake and are and are and are and are .... preventable by preventable by preventable by preventable by Mistake-proofingMistake-proofingMistake-proofingMistake-proofing (Poka-Yoke). (Poka-Yoke). (Poka-Yoke). (Poka-Yoke).
� Manufacturing Excellence is sustained by building a Manufacturing Excellence is sustained by building a Manufacturing Excellence is sustained by building a Manufacturing Excellence is sustained by building a . . . . CI CI CI CI ....Knowledge BankKnowledge BankKnowledge BankKnowledge Bank to to to to revise the PMrevise the PMrevise the PMrevise the PM shut-down Job-shut-down Job-shut-down Job-shut-down Job- . . . . listlistlistlist and and and and shared shared shared shared totototo AM activities AM activities AM activities AM activities.... 3
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)
Model Machine
Current PM Job-list Items
Current Items that Need Revision of Stds
New items to be added to PM Job-list
Current PM Job-list items that are OK
NEW PM Job-list items (Total QTY)
AM3 final recommended list
FPP Bagging
36 items 16 44 20 80 items 49 items
NPP Extruder
22 items 4 51 18 73 items 19 items
Enhanced Enhanced Enhanced Enhanced PM Joblist PM Joblist PM Joblist PM Joblist ((((At End of At End of At End of At End of AMAMAMAM Step Step Step Step 3) 3) 3) 3) Real SampleReal SampleReal SampleReal Sample
FM FM FM FM PacPacPacPackkkkGND GND GND GND CutCutCutCut
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 history Breakdown history Breakdown history Breakdown history
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-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.
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Start at Start at Start at Start at AMAMAMAM0 - Baseline Status0 - Baseline Status0 - Baseline Status0 - Baseline 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.
to the roller printer. 1a3) Cleaning the air f ilter. BD#1a - Vac Cup Suction Low * No standing space to remove and
1a1) Suction cup w orn/harden replace f ilter.1a2) Suction tubes loose/broke1a3) Air f ilter clogged 1a3) Air f ilter clogged Other BMC Groups1a4) Pump impeller broke * Water f rom air suppy IA. 1a4) Pump impeller 1a5) Pump motor burned * Collected on f ilter 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 f ilter performance * Inside assembly cannot see.
1b1) Cylinder leakage w ithin 2 w eeks. 1a6) Pump bearing w orn1b2) Solenoid valve jammed * Inside assembly cannot see.1b3) Air f ilter clogged 1b4) No w ater trap
Future BD Areas to be investigated: BMCsBMCsBMCsBMCs fromfromfromfrom FuguaiFuguaiFuguaiFuguai FoundFoundFoundFound DescribeDescribeDescribeDescribe ContaminationContaminationContaminationContamination AccessibilityAccessibilityAccessibilityAccessibility problemsproblemsproblemsproblemsContamination
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 electhousing 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 f rom 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 electw ires and joints.
More Before & After Pictures
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(Note: Need To Raise Maintenance Work Order For F-Tag Repairs)
MACHINE:MACHINE:MACHINE:MACHINE: ASM5500QUESTIONS ABOUT CONTAMINATION SOURCE QUESTIONS ABOUT CONTAMINATION SOURCE QUESTIONS ABOUT CONTAMINATION SOURCE QUESTIONS ABOUT CONTAMINATION SOURCE DURING INVESTIGATIONSDURING INVESTIGATIONSDURING INVESTIGATIONSDURING INVESTIGATIONS
ACTUAL FACTS COLLECTED ACTUAL FACTS COLLECTED ACTUAL FACTS COLLECTED ACTUAL FACTS COLLECTED SKETCH THE CONTAMINATION FALL-PATHSKETCH THE CONTAMINATION FALL-PATHSKETCH THE CONTAMINATION FALL-PATHSKETCH THE CONTAMINATION FALL-PATH
MACHINE SECTION:MACHINE SECTION:MACHINE SECTION:MACHINE SECTION: Waferhandler - Port1 1111 What is it?What is it?What is it?What is it? Broken silicon piecesBroken silicon piecesBroken silicon piecesBroken silicon pieces2222 Where is the source? Where is the source? Where is the source? Where is the source? Wafer protruding from Port1 Elevator cassette3333 How the contamination got there? (The Fall-Path)How the contamination got there? (The Fall-Path)How the contamination got there? (The Fall-Path)How the contamination got there? (The Fall-Path) Not fully inserted because cassette was not seated
properly then smashed against lid housing upon port initialise
CONTAMINATION TYPE:CONTAMINATION TYPE:CONTAMINATION TYPE:CONTAMINATION TYPE: Broken wafer 4444 Why is the contamination there?Why is the contamination there?Why is the contamination there?Why is the contamination there? Wafer not fully inserted5555 When it get there?When it get there?When it get there?When it get there? Upon impact with underside of lid housing
REFERENCE # :REFERENCE # :REFERENCE # :REFERENCE # : CONTAMINATION BASELINECONTAMINATION BASELINECONTAMINATION BASELINECONTAMINATION BASELINE BASELINE MEASUREMENTBASELINE MEASUREMENTBASELINE MEASUREMENTBASELINE MEASUREMENTa)a)a)a) HOW MUCH? ( volume, weight, count or an actual HOW MUCH? ( volume, weight, count or an actual HOW MUCH? ( volume, weight, count or an actual HOW MUCH? ( volume, weight, count or an actual
sample)sample)sample)sample)1 broken wafer on 5 areas indicated
CONTAMINATION EFFECT :CONTAMINATION EFFECT :CONTAMINATION EFFECT :CONTAMINATION EFFECT :b)b)b)b) HOW LONG? - (Record the time for the Qty of HOW LONG? - (Record the time for the Qty of HOW LONG? - (Record the time for the Qty of HOW LONG? - (Record the time for the Qty of
contamination to accumulate) contamination to accumulate) contamination to accumulate) contamination to accumulate) 6 Months
Areas difficult orAreas difficult orAreas difficult orAreas difficult orinaccessible for cleaninginaccessible for cleaninginaccessible for cleaninginaccessible for cleaningchecking & lubricatingchecking & lubricatingchecking & lubricatingchecking & lubricating
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.
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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.
Continuous Im provem ent W orksheet For Updating PM Standards Job-list Item sContinuous Im provem ent W orksheet For Updating PM Standards Job-list Item sContinuous Im provem ent W orksheet For Updating PM Standards Job-list Item sContinuous Im provem ent W orksheet For Updating PM Standards Job-list Item sToolset N ame: Toolset N ame: Toolset N ame: Toolset N ame:
B D #1 Tubes jamB D #1 Tubes jamB D #1 Tubes jamB D #1 Tubes jam M 70SW 11 u/s v Addblocked drive v v ReviseDegraded proxim ity switch v Add
battery valve u/s v Addrot.drive jam , v NCAM 2 C-measures access panel Add
rot.drive jam , v Addproxim ity switch worn v Addtube tower dirty v v Revisecylinder leak v Addsingulator fingers loose v Addtube 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 Unit 1. Base Unit 1. Base Unit 1. 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 items PM items PM items PM items D ecision D ecision D ecision D ecision a) no change b) revise stds c) add to PM list
Information source Information source Information source Information source (BD/Def/Fuguai/) (BD/Def/Fuguai/) (BD/Def/Fuguai/) (BD/Def/Fuguai/)
System ID - System ID - System ID - System ID - Drive/Elect/Pnue/Hd
y/W ater………… ........
Assy Assy Assy Assy overall overall overall overall function function function function
Early W arning Signs Early W arning Signs Early W arning Signs Early W arning Signs (M C or Product)(M C or Product)(M C or Product)(M C or Product)
M aint Parts M aint Parts M aint Parts M aint Parts Repaired/ ReplacedRepaired/ ReplacedRepaired/ ReplacedRepaired/ Replaced
AM Operators becomes Maintenance DeptAM Operators becomes Maintenance DeptAM Operators becomes Maintenance DeptAM Operators becomes Maintenance Dept’’’’s extra s extra s extra s extra ““““ears, ears, ears, ears, eyes, hands, noseeyes, hands, noseeyes, hands, noseeyes, hands, nose”””” to detect early signs of MC trouble and to detect early signs of MC trouble and to detect early signs of MC trouble and to detect early signs of MC trouble and
thus helped to change Un-Planned Events into Planned thus helped to change Un-Planned Events into Planned thus helped to change Un-Planned Events into Planned thus helped to change Un-Planned Events into Planned Events (Planned Maintenance)Events (Planned Maintenance)Events (Planned Maintenance)Events (Planned Maintenance)
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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.
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
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
11112222333344445555
66667777
8888 14141414
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 a ll 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 Result4M Correlation,
Second Item Investigation/ Investigation Result If NG, Countermeasure Result
Investigation M easuring Method
Temporary Decision Criterion
Measure - ment Value
DecisionInvestigation/ Measuring
MethodTemporary
Decision CriterionMeasure -
ment ValueDecision
(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. INCOMPLETEOR INSUFFICIENTDEPTH OF 9 - 11 mils 7 mils NG 3.1 Deterioration 0.49 W - 0.46 W NG 0.50 W OKCHARACTERS of laser Engraver 0.52WON STAMP PLATES. beam power
SIDESIDESIDESIDE VIEWVIEWVIEWVIEW OFOFOFOF PLATEPLATEPLATEPLATE Laser after powerdeterioration
Actual Laser
Characters not beenengraved deeply caused illegible marking. Characters not been
engraved deeply caused illegible marking.
2. Uneven stamp Even layer No method NGplate layer. to measure
3. Residue ink on No ink residue Have ink NG 1. Not fully 1. To immerge 60 to 65 mm OKused 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 OKimmerge stamp immerge the plate 30 minin acetone. after use. after 3. Stamp plate usednot cleanedproperly.4. Acetone 4. To change the No No OKcontainer dirty. acetone 2x per week Illegible Illegible
marking. marking.
Design of Experiments During P-M Analysis For Design of Experiments During P-M Analysis For Design of Experiments During P-M Analysis For Design of Experiments During P-M Analysis For Chronic DefectsChronic DefectsChronic DefectsChronic Defects
OEE = Availability x Performance Rate x Quality Rate
OEE Loss Analysis ChartQuantity Vs Time 2-D Chart (More Useful)
Speed Loss(Company gap)
MTBA & Idling
Quality Loss
Speed Loss (World class gap)
Availability Loss
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 motivationVisit www.leantargetcosting for a software solution.
Using Costs To Drive C.I. Activities Software uses Toyota Principles, TPM OEE, Lean 6S.
Watch on Youtube, Youku, Vimeohttps://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
Notes:1. The Process Yield Project can reduce the Process Cost by 9.21% (Rank 1 ticked)
Note: Red numbers are Cost-Reductions adjusted to Baseline conditions to eliminate noise.