T otal P roductive M aintenance TPM

Total Productive MaintenanceTPM

Overview

Dave Hoyte, CEOJL French Corporation

TPM as a Lean InitiativeCompetitive costs require

◦Spending control◦Defect control ◦Downtime reduction

TPM = Total Productive Maintenance◦Proactive (with all employees

involved)◦Preventive◦Predictive◦Planned

Why Change?ACTIONS:

◦Reduce defectives / scrap◦Reduction of lost production time◦Lowest possible cost by reducing waste

Lean System

5S Visual Factory

T P MStandardized

Work

Leadership by Example & CommitmentIn-Station Process Control

Lean Measures

Employee Involvement & Mutual Respect

Pull system / flow production

Peak Performance

Variation reduction / Six Sigma

Continuous Waste ReductionRapid Changeover / Customer-driven lot size

7 WastesTransportationExcess productionAdded processesMotion

Waiting InventoryNon-conformance

(defectives)

Causes of WasteExcess Manning

◦ Poor layout and material presentation◦ Rework and extra processes ◦ Inconsistent / inefficient work methods

Excess Downtime◦ Tooling condition ◦ Unreliable equipment◦ Long changeovers◦ Incapable process

Defectives - Rework or Replace◦ Incapable processes or process not

compatible with customer expectations or design spec (design for mfg)

◦ Tooling condition◦ Operator methods and errors

Causes of WasteExcess Manning

◦ Poor layout and material presentation◦ Rework and extra processes ◦ Inconsistent / inefficient work methods

Excess Downtime◦ Tooling condition ◦ Unreliable equipment◦ Long changeovers◦ Incapable process

Defectives - Rework or Replace◦ Incapable processes or process not compatible

with customer expectations or design spec (design for mfg)

◦ Tooling condition◦ Operator methods and errors

Effective TPM Eliminates 5 Losses

1. Equipment breakdowns2. Defects, scrap, and rework3. Safety Issues4. Mini stoppages5. Reduced speed

What is TPM??

1. Starts with 5S / Visual Factory2. Builds a comprehensive Downtime

Database by cause, frequency, and duration

3. Predicts and prevents downtime by PM system

4. Expands role of Operator as first point of early warning and prevention

5. Develops Professional Maintenance skills

TPM is a Lean tool to optimize the effectiveness of manufacturing equipment and tooling.

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Operator Autonomous Maintenance

Countermeasures for Contamination

Initial Standards

General Inspection

Autonomous Inspection

Standardization

Aut. Mgt.Seven Steps of TPM

7

6

5

4

3

2

1Initial Clean-up

TPM is Planned, Predictive, & Preventive

1. Starts with 5S / Visual Factory2. Builds a comprehensive downtime

data base by cause, frequency, and duration

3. Predicts and prevents downtime by PM system

4. Expands role of Operator as first point of early warning and prevention

5. Professional Maintenance

5S Workplace

Sort (organize)Shine (clean) Set in order (make orderly and neat)Standardize (visual place for

everything)Sustain (maintain the system)

A safe, clean, orderly workplace is fundamental to quality, efficiency, and teams

TPM starts with 5SYou can’t see problems clearly

when the workplace is in disarrayCleaning and organizing the

workplace helps the team to uncover problems

Making problems visible is the first step of improvement

Clean machines and workplace create pride & Safety

Downtime Visual Controls

Visual or audio alerts ◦Abnormality obvious at a glance (e.g.

stoppage, reject, control fault)◦Alerting Maint and team leaders◦Provide real time “scoreboard” for

employees Machine down light visible from aisle Production status board (e.g. actual counts

vs. goal) Scrap counts and downtime minutes Located in clear view in shop (not in control

room) Simple, self regulating, & employee managed

TPM is Planned, Predictive, & Preventive

1. Starts with 5S / Visual Factory2. Builds a comprehensive

downtime data base by cause, frequency, and duration

3. Predicts and prevents downtime by PM system

4. Expands role of Operator as first point of early warning and prevention

5. Professional Maintenance

Downtime DatabaseCategorize at a minimum by Equip, Tooling, C/O,

OtherSegmented bar graph for E-T-O lost timeSubcategories for Equip (e.g.)

◦ Hydraulic / pneumatic◦ Mechanical / lubrication◦ Electrical / controls◦ Shot-end components

Subcategories for Tooling (e.g.)◦ Slides◦ Cores◦ Inserts◦ Ejector pins

Subcategories for Other (e.g.)◦ Operator error◦ Materials

Minimum Downtime Tracking

0

20

40

60

80

100

120

Minutes

1Q02 2Q02 Jun Jul Aug Sep Oct Nov Dec

Downtime by Cause 3500 ton Bay(avg min/shift per Machine)

OTE

Equip

Tools

Other

TPM is Planned, Predictive, & Preventive

1. Starts with 5S / Visual Factory2. Builds a comprehensive downtime

data base by cause, frequency, and duration

3. Predicts and prevents downtime by PM system

4. Expands role of Operator as first point of early warning and prevention

5. Professional Maintenance

Predictive Maintenance ToolsRate/hr vs. target or historical normal output (B/W)

Database ◦ MP2 / maintenance history◦ statistical probability (frequency & duration)

Physical prediction of impending failure◦ Sound (bearing)◦ Temperature (cooling water)◦ Flash (core pins) ◦ Shot monitoring system ◦ SPC on part geometry ◦ Hydraulic pressure (ejector pins)◦ Spindle loads (amps) ◦ Fluids / Lubrication analysis (milipore)◦ Vibration Signature Analysis

Preventive Maintenance System History of downtime by major machine & tool

◦ Downtime measurement & tracking◦ Mean Time Between Failures◦ Average downtime◦ Pareto of causes at component level (eg L/S or temp sensor)◦ Cost to maintain

Develop PM cards based on frequency of failure and magnitude of average lost time (start small & grow)◦ Limit & prox switches◦ Shot tip / sleeve◦ Critical frame and cylinder mounting bolts◦ Expendable tools◦ Valves, hoses, packing, seals

PM’s have instruction, schedule/frequency & sign-off ◦ PM’s / repairs done in window of opportunity when machine is

down◦ Cycle count or date based execution of PM’s (eg cutter

change)◦ PM status visual (work completed / not completed)

TPM is Planned, Predictive, & Preventive1. Starts with 5S / Visual Factory2. Builds a comprehensive downtime data

base by cause, frequency, and duration3. Predicts and prevents downtime by PM

system 4. Expands role of Operator as first

point of early warning and prevention One point lessons for operator

awareness Creates OMP (Operator -

Maintenance Partnership) Operator performs checks, problem

solving, and improvements5. Professional Maintenance

TPMProduction Operators

• Clean & Check• Observe• Categorize

Manufacturing Engineers• Equipment Planning• Equipment Studies

Production Planning & Control

• Schedule P.M.

Quality Engineers• Standards &

Calibrations

ActivePlanned

MaintenanceProcess

OMP - Operator Maintenance Partnership

Operator training in TPMOperator basic equip

inspection & tooling checksOperator basic cleaningOperator lubrication checkOne point lessons (capture

knowledge)TPM Board & TPM Tags

(proactive operator involvement)

TPM

TPM Tag SystemProblem communication tool to and from

maintenance, tool room, and production◦ Identify abnormal machine conditions

Record problem discovered by operator Record problem found during scheduled PM

◦ Status tracking system of requested repairs◦ TPM visual management tool (hang tags)◦ Repair history for future problem solving

TPM Tag used for recording problem & fix◦ Blue Tag-Operator or Maint responsible to repair◦ Red Tag- Safety-related request (priority)

Operator/Supervisor Production Management Maintenance

1. Abnormality Identified

2. Fill out Tag Red= Safety Blue= Prod/Maint

3. Hang C-tag as close to the defect as possible

4. Hang A &B Tags on the TPM Tag status board by Machine location and area of responsibility to correct.

5.Maintenance evaluates problem. If fixed immediately go to 6. If parts or time needed, maint pulls A tag from board. The A tag is MWO. The B tag is posted on the Maint WO status section of the TPM Board with est. timing.

7. Operator/Supervisor check to see if work was done.

6.After work is completed, maintenance completes back side of A tag and places both the A & B tag in the work completed box

8. If OK, Operator/ supervisor removes C tag from machine and places ABC tags in Completed box. If not OK, tags stay and maint is contacted. Contact noted on tag.

9. Production management reviews the information. Also reviews the comments and takes actions if required. Places tag in history file box located in the office

Tag information is recorded and reviewed for continuous improvement of PM database by Production and Maintenance; Repeat operator tags may indicate Maint needs to investigate.

Tag Process

TPM is Proactive, Predictive, Preventive & Planned

1. Starts with 5S / Visual Factory2. Builds a comprehensive downtime

data base by cause, frequency, and duration

3. Predicts and prevents downtime by PM system

4. Expands role of Operator as first point of early warning and prevention

5. Professional Maintenance

Professional MaintenanceEquip SafetySkill buildingCross-trainingArea MaintenanceWC MRO storesMaint Mgmt SystemDown alarmsRadios Planned PM

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Operator Autonomous Maintenance

Countermeasures for Contamination

Prepare Temporary Standards

General Inspection

Autonomous Inspection

Standardization

Aut. Mgt.

7 Steps

7

6

5

4

3

2

1Initial Clean-up

OIL

T P M

TPM

5S

TPM IStep 1Step 2Step 3

TPM IIStep 4 Step 5Step 6Step 7

Initial Focus

prerequisite for TPM I

STEP 3: Prepare Temporary Standards

This step is to enhance the equipment reliability & maintainability.Temporary Check Sheet For Clean-

Up, Lubrication, Start-up, and Shut-

down:◦ What items need to be done◦ Who will perform the check◦ How often to check◦ Where the location is to be checked◦ What to use for the inspection or

cleaning◦ Target time to complete the task

TPM SummaryTPM = Total

Productive Maintenance◦ Proactive (all

employees involved)◦ Preventive◦ Predictive◦ Planned

TPM is an integral part of JLF Total Quality production System

5S Visual Factory

T P MStandardized

Work

Continuous Waste Reduction

Peak Performance

TPM is a Lean tool for Quality and Productivity