TPM Focused Improvement - · PDF fileTPM Overview 1. Operators and ... 7. A CULTURAL SHIFT. What changes? OLD ATTITUDE ... for machine abnormalities. The majority of maintenance problems

TPM Focused Improvement Introduction Slides

Team Member Introductions

• Your Name

• Role

• # of Years with CCM

• # of Kaizen events in which you’ve participated

• Something interesting nobody else in this room knows about you

• What are your expectations for this event?

Kaizen Event Ground Rules

• Keep an open mind to change

• Leave your titles at the door

• No idea is a bad idea

• Do not leave in silent disagreement

• No cell phones except during breaks

• One person, one voice

• Mutual trust & respect

Seven Types of Waste

• Transportation

• Overproduction

• Motion

• Defects

• Waiting

• Inventory

• Excessive Processing

Three Value-Added Requirements for Process Step

• Something physically changes

• Done correctly the first time

• Customer must be willing to pay

What is TPM?

TPM Overview

1. Operators and Maintenance working together

2. Improved safety

3. Operators taking more ownership of their equipment

4. Maintenance time freed up to work on higher-level tasks

5. Reduced downtime and improved quality

6. Reactive Proactive system

7. A CULTURAL SHIFT

What changes?

OLD ATTITUDE

“ I Operate, YOU Fix ”“ I Fix, YOU Design ”

“ I Design, YOU Operate ”

NEW TPM ATTITUDE

“ WE ARE ALL RESPONSIBLE FOR OUR EQUIPMENT”

A successful implementation requires: Total employee involvement

Operator Autonomous Maintenance

• A system in which operators are able to:

– Perform daily checks

– Lubricate equipment as needed

– Replace simple components

– Perform minor repairs on machines

– Assist in problem solving

Operators become the early warning systemfor machine abnormalities

The majority of maintenance problems can be detected by machine operators trained to find the problems at an early stage

100% Compliance with Safety ChecklistA LOCK OUT/TAG OUT PROCEDURES IN PLACE & DOCUMENTED

CHECKLIST (Yes/No)

1 Machine specific procedures are written and accessible

2 All energy sources and isolation points are identified

3 Isolation devices, locks & tags are available and single keyed

4 Authorized trained personnel are to lead all lock out/tag out operations

B ARC FLASH PROTECTION CHECKLIST (Yes/No)

1 Authorized trained personal perform all electrical panel maintenance

2 PPE is available and utilized when performing electical panel maintenance (when required)

C PORTABLE FIRE EXTINGUISHERSCHECKLIST (Yes/No)

1Portable fire extinguishers shall be mounted, located and identified so that they are readily accessible to employees

2Only approved portable fire extinguishers shall be used ( no carbon tetrachloride or chlorobromomethane extinguishing agents)

3Portable fire extinguishers shall be maintained in a fully charged and operable condition and kept in their designated places at all times except during use

D EYEWASH STATIONSCHECKLIST (Yes/No)

1Eyewash stations must be on the same level as the hazard, there can be nothing blocking the way to the emergency station and reachable within 10 seconds from the hazard

2Employees who will be working with hazardous materials must be trained in how to properly use eyewash stations as well as where they are located

3Hard plumbed eyewash stations are activated monthly to flush & test. Portable eyewash stations are checked monthly to verify that the reservoir is full and the unit has not been activated since the last service

4 All eyewash stations must have posted visual operating instructions

E MAINTENANCE PERSONAL PROTECTIVE EQUIPMENTCHECKLIST (Yes/No)

1Maintenance Personal Protective Equipment has been defined and procedures have been established and defined

2 Maintenance personal have been trained in the established procedures

3 Proper PPE is available and inspected on a regular basis

F POWERED INDUSTRIAL VEHICLESCHECKLIST (Yes/No)

1 Only trained, certified maintenance personal may operate power-industrial vehicles

2 A daily operator checklist is in use for fork trucks

3 A PM program is established to insure safe operating conditions are maintained

G HOISTS & LIFTING EQUIPMENTCHECKLIST (Yes/No)

1 Annual inspections and maintenance records are maintained for:

2 Hoists & Cranes

3 Slings & Chains

4 Lifting Jigs (below the hook)

H CONFINED SPACECHECKLIST (Yes/No)

1

There is a confined space entry program in place including an entry permit (written or printed document that is provided by the employer to allow and control entry into a permit space) where employees are required to enter confined spaces.

2 Confined spaces are clearly identified and labeled.

I LADDERSCHECKLIST (Yes/No)

1Ladders shall be inspected by a competent person for visible defects on a periodic basis and after any occurrence that could affect their safe use.

2

Portable ladders with structural defects, such as, but not limited to, broken or missing rungs, cleats, or steps, broken or split rails, corroded components, or other faulty or defective components, shall either be immediately marked in a manner that readily identifies them as defective, or be tagged with "Do Not Use" or similar language, and shall be withdrawn from service until repaired.

3When not in use, portable ladders are stored in a manner which prevents them from toppling. (IE, secured by chain)

J MACHINE GUARDINGCHECKLIST (Yes/No)

1An evaluation has been made of each piece of critical equipment for proper guarding. All guarding is functional and in good repair.

K FIRE PROTECTION IMPAIRMENT HANDLING - FM GlobalCHECKLIST (Yes/No)

1 Is the FM Global Red Tag Kit hanging and accessible?

2 Are FM Global Red Tag Permits available and accessible?

3Has the FM Global online training course "Managing Impairments Using FM Global's Red Tag Permit System" been completed by those personnel responsible for managing fire protection impairments?

L HOT WORK -FM GlobalCHECKLIST (Yes/No)

1 Is the FM Global Hot Work Kit hanging and accessible?

2 Are FM Global Hot Work Permits available and accessible?

3Has the FM Global online training course "Managing Hot Work Using FM Global's Hot Work Permit System" been completed by those personnel responsible for conducting or monitoring hot work?

M FIRE PROTECTION INSPECTIONS - FM GLOBALCHECKLIST (Yes/No)

1 Is the FM Global Fire Protection Inspection Checklist available and accessible?

2 Are all sprinkler valves listed on the checklist?

3 Is the checklist being completed on a weekly basis?

4Has the FM Global online training course "Inspecting Fire Protection Valves" been completed by those personnel responsible for inspecting the fire protection system?

Equipment Criticality Form

DEPARTMENT:

LOCATION:

RETURN TO:

CRITERIA SCORING RATING

EIGHTY PERCENT OR ABOVE 5

FIFTY TO EIGHTY PERCENT 3

FIFTY PERCENT OR BELOW 2

NO (ONE OF KIND) 5

YES (AT ANOTHER COMPANY) 4

YES (AT THIS COMPANY) 1

AFFECTS THE ENTIRE PLANT 5

IMPACTS OTHER PROCESSES 4

ONLY AFFECTS ONE MACHINE 1

$1000.00 OR MORE 5

$500.00 TO $1000.00 4

UNDER $500.00 2

DECISIVELY 5

SOMEWHAT 2

NOT SIGNIFICANTLY 1

$1000.00 OR MORE 5

$500.00 TO $1000.00 4

UNDER $500.00 2

OVER 3 HOURS 5

1 TO 3 HOURS 4

UNDER 1 HOUR 2

ALL QUESTIONS ARE "YES" 5

TWO THIRDS ARE "YES" 4

ONE THIRD ARE "YES" 1

PRIORITY: TOTAL 0

TPM: EQUIPMENT CRITICALITY FORM

PURPOSE: TO IDENTIFY AND PRIORITIZE EQUIPMENT AND MACHINERY FOR TPM EVENT

EQUIPMENT NAME:

EQUIPMENT #:

AGE (YEAR): FOOTPRINT(SQ/FT):

DATE FOR TPM:

PRODUCTION

1 HOW OFTEN IS THE EQUIPMENT USED EACH DAY? 0

2 IS THERE BACK-UP EQUIPMENT OR PROCESS AVAILABLE? 0

3TO WHAT EXTENT WILL A FAILURE OF THIS EQUIPMENT

AFFECT OTHER PROCESSES?0

QUALITY

4WHAT IS THE AVERAGE MONTHLY VALUE OF SCRAP OR

REWORK PRODUCED BY THIS EQUIPMENT? 0

5HOW WILL THE PROCESSES RUN ON THIS EQUIPMENT

AFFECT THE FINAL QUALITY OF THE FINISHED PRODUCT?0

MAINTENANCE

6WHAT IS THE AVERAGE MONTHLY COST OF REPAIRS TO

THIS EQUIPMENT?0

7WHAT IS THE AVERAGE TIME IT TAKES TO REPAIR THIS

EQUIPMENT?0

SAFETY &

ENVIRONMENT8

DO SAFETY ENHANCEMENTS NEED TO BE APPLIED? IS THE

EQUIPMENT CURRENTLY LEAKING? DOES A HOUSEKEEPING

SCHEDULE NEED TO BE DEVELOPED?

0

(HIGH=A) 32-40, (MEDIUM=B) 22-31, (LOW=C) 12-21

Condition Code Form

Plant:

Department #:

Location:

0 Equipment Criticality

0 = No Repair Needed

1 = Minor Repairs Expense

2 = Major Repairs

3 = Semi-overhaul

4 = Rebuild/ Retrofit/ Replace? Capital $$

5 = Obsolete/ Replace

Comments:

Comments:

Comments:

Comments:

Comments:0 Mechanical systems

0 Hydraulic system

0 Motors/ Drives

0 Controllers/ PLC

Critical Equipment Condition Code Form

Name:

Asset #:

Description:

Condition Code

0 Pneumatic system

Focused Improvement Checklist

A Clean to InspectCHECKLIST

(Yes/No)

1 Lock-out/Tag-out the equipment before cleaning or inspecting

2 Clean and & inspect all visible external components of the equipment

3 Remove all panels & covers to deep clean and inspect internal components

B Identification of defects/opportunitiesCHECKLIST

(Yes/No)

1 Use blue tag process or flip chart at machine to collect defect issues/opportunities

2 Document contamination, lubrication, excess wear, damaged, missing or unknown component issues

3 Summarize and prioritize defects issues/opportunities

CMachine basic conditions are identified & restored. Countermeasures are

implemented for prevention

CHECKLIST

(Yes/No)

1Correct machine conditions are identified for documented defects/issues (tightness, speed, torque,

pressures, temperatures, cleanliness)

2 Machines conditions are restored to correct specifications

3Countermeasures are implemented to prevent reoccurrence of issues (filtering, sealing, guarding and

improved access & visibility)

D Visual Controls implemented that easily identify abnormal conditions (Yes/No)CHECKLIST

(Yes/No)

1 Gauges should have markings that visually identify correct operating parameters (Green/Red)

2 Critical fasteners are match marked

3 Min/Max fluid levels are identified and easy to see

4 Air flow is visible (i.e. streamers on cooling fans)

5 Motor temperature strips are installed

TPM FOCUSED IMPROVEMENT PROCESS CHECKLIST

Critical Equipment Name: _________________________________

TPM Focused Improvement Process

A. Clean to Inspect

A Clean to InspectCHECKLIST

(Yes/No)

1 Lock-out/Tag-out the equipment before cleaning or inspecting

2 Clean and & inspect all visible external components of the equipment

3 Remove all panels & covers to deep clean and inspect internal components

B. Identify Defects/OpportunitiesB Identification of defects/opportunities

CHECKLIST

(Yes/No)

1 Use blue tag process or flip chart at machine to collect defect issues/opportunities

2 Document contamination, lubrication, excess wear, damaged, missing or unknown component issues

3 Summarize and prioritize defects issues/opportunities

C. Restore Machine Conditions

CMachine basic conditions are identified & restored. Countermeasures are

implemented for prevention

CHECKLIST

(Yes/No)

1Correct machine conditions are identified for documented defects/issues (tightness, speed, torque,

pressures, temperatures, cleanliness)

2 Machines conditions are restored to correct specifications

C. Implement Countermeasures

CMachine basic conditions are identified & restored. Countermeasures are

implemented for prevention

CHECKLIST

(Yes/No)

3Countermeasures are implemented to prevent reoccurrence of issues (filtering, sealing, guarding and

improved access & visibility)

We can inspect and lubricate without

locking out…

Countermeasure Examples

Some guards / panels are expanded

Metal. Sturdy, but we cant see inside.

Operator inspection is difficult.

By painting the grating black, we can now

easily check for abnormalities.

D. Implement Visual Controls

E. Operator Autonomous Maintenance

1) Mark critical areas of equipment.

2) Check sequentially, beginning of each shift - Pressure gages/oil levels/contamination/leaks, etc.

3) Look for abnormal operating conditions notify Maintenance if found.

4) Should not take more than 5 minutes, typically about 2 minutes

Operator Autonomous MaintenanceDaily Operator PM Wolters Lapper

1. Check lower cavity fan filter. Replace when dirty.

2. Check gearbox oil reservoir sight glass.

3. Check water pressure gage. Should be in green range.

4. Check electrical cabinet air flow ribbon for movement.

5. Check electrical cabinet air filter. Replace when dirty.

6. Check refrigeration air flow ribbon for movement.

7. Check refrigeration temperature controller. Temperature

should be between 60 – 70 degrees F.

8. Check refrigeration cooling air filter. Replace when dirty.

9. Check incoming air pressure. Should be in green range.

10. Check filter paper waste bin. Remove dirty paper as

required.

Operator Autonomous Maintenance

OAM Checklist Example (F-370)

F. Establish Maintenance PMs

F Specific maintenance P.M.’s are established for the machine & optimized CHECKLIST

(Yes/No)

1 Preventive maintenance schedule (based on time or cycle) has been created for equipment

F Specific maintenance P.M.’s are established for the machine & optimized CHECKLIST

(Yes/No)

2 An equipment specific detailed checklist has been created for PM steps

3 PM optimization has been utilized (i.e. part of operator autonomous PM, use of predictive tools)

4 Accurate time standards are established for PM's

G. Establish Spare Parts Inventory

GThe spare parts inventory has been established and/or updated for this

equipment

CHECKLIST

(Yes/No)

1 Critical spare parts has been created with costs, lead time and risk to customer OTD

2 Critical spare parts have been reviewed with management

3 Critical spare parts that have been approved for purchase are in stock

H. Close-out

H TPM FOCUSED IMPROVEMENT CLOSE-OUTCHECKLIST

(Yes/No)

1 Document the steps completed using the checklists

2 Reveiw open defects/issues and opportunities with operations/maintenance management

3

Review the checklist with operations and mainteance mangement, go to equipment and review

improvements, operator autonomous maintenance process, maintenance excellece metrics and have

management signoff on this document.

Why TPM?

2 Major Causes of Breakdowns

Example

• From Fidel Mendoza, Safety & QA Engineer at the Montgomery, NY, Polyiso plant

Why Should You Care?

• Line 1 Lift Table: June 6, 2015– Down time: 14 hours

– Cost to repair: $1260• 2 Maintenance techs

• 1 Forklift driver

– Change product on Line 1 to HD

• What should it have cost?– $0

– The failure was completely preventable

How Did It Break?

• 5-11-15, Steve Grogan:– Issue with line 1 Line drivers table leaking

hydraulic fluid, found return line was disconnected. Reconnected the return line.

• This repeats several times a week!

• Oil level drops

• Hose goes dry

• Pump no longer pumps

• Lift table stops lifting

How TPM Prevents This Problem

• Evaluate equipment for ways to make it easier to maintain– How can we know if the hydraulic fluid level is low?– How can we know if the pump is giving enough pressure?– How can we know if the motor is taking too much electricity?

• Add visual controls– Fluid level gauge with marked fill level– Hydraulic pressure gauges

• Add shift operator checks– Is the fluid too low or too high?– Is the pump pressure in spec?

• Fix it before it breaks!

So What Would Have Happened?

• Line Driver notices that hydraulic fluid level is low

• He either fills it or asks Maintenance to fill it

• Line Driver notices the hydraulic pressure is out of the green

• He notifies Maintenance, even though the table still works

• Maintenance troubleshoots the problem on a non-production shift

TPM – Summary

• Operators taking more ownership of their equipment

• Visual controls for quick & easy Operator Autonomous Maintenance

• Proactive rather than Reactive system

• Countermeasure implementation to prevent future problems, like the Montgomery lift table

• Shift in the culture!