tpm/moses 1 ZenPower International Industry TPM Consultants Moses Tan (MSc, BIT), is the Principal TPM Consultant of his own Consultancy Company, ZenPower International, since 1996. He was formerly TPM manager of a TDK company for 6 years. His clients include Local, Western, Japanese MNCs in the IC Assembly, Test & Plating, SMT, Materials, Auto parts industries. Website: www.tpmquality.com
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tpm
/mos
es1
ZenP
ower
Inte
rnat
iona
lIn
dust
ry T
PM C
onsu
ltant
sM
oses
Tan
(MSc
, BIT
), is
the
Prin
cipa
l TPM
C
onsu
ltant
of h
is o
wn
Con
sulta
ncy
Com
pany
,Ze
nPow
er In
tern
atio
nal,
sinc
e 19
96. H
e w
as
form
erly
TPM
man
ager
of a
TD
K c
ompa
ny fo
r 6
year
s. H
is c
lient
s inc
lude
Loc
al, W
este
rn,
Japa
nese
MN
Cs i
n th
e IC
Ass
embl
y, T
est &
Pl
atin
g, S
MT,
Mat
eria
ls, A
uto
parts
indu
strie
s.
Web
site
: w
ww
.tpm
qual
ity.c
om
tpm
/mos
es2
TPM
OV
ERV
IEW
Man
ufac
turi
ng &
Adm
inis
trat
ive
Exc
elle
nce.
tpm
/mos
es3
Bac
kgro
und
of T
PM•
Mai
n m
anuf
actu
ring
exc
elle
nce
appr
oach
of T
oyot
a an
d ot
her
exce
llent
Jap
anes
e co
mpa
nies
sinc
e th
e 70
’s.
•T
PM is
foun
datio
nfo
r JI
T, F
A, P
oka
Yok
e, L
ean
Man
ufac
turi
ng, Z
ero
Def
ects
.
•T
PM R
efer
ence
Sta
ndar
d -
JIPM
(Jap
an In
stitu
te o
f Pla
nt
Mai
nten
ance
)•
Com
es fr
om th
e be
st o
f Jap
anes
e In
dust
rial
Exc
elle
nce
and
evol
ved
from
the
heat
of t
he c
ontin
uing
Ene
rgy
Cri
sis a
nd
Glo
baliz
atio
n ch
alle
nges
to a
chie
ve M
ore
with
Les
s.
tpm
/mos
es4
TP
M G
OA
LST
PM
GO
ALS
1.In
crea
se a
sset
Util
izat
ion
and
Equi
pmen
t OEE
2.Fo
ster
Pro
duct
ion
Equi
pmen
t Ow
ners
hip
3.Eq
uipm
ent b
reak
dow
n pr
even
tion
( Pla
nned
M
aint
enan
ce th
roug
h C
M, T
BM
, CB
M)
4.D
efec
t Pre
vent
ion
(QM
Pro
cess
& P
oka
Yok
e )
5.Ev
olvi
ng in
to S
elf D
irect
ed W
ork
Team
s
(S
DW
Ts) a
nd L
ean
Man
ufac
turin
g.
tpm
/mos
es5
JIP
M S
TA
ND
AR
DS
1.T
PM S
truc
ture
& O
rgan
izat
ion
2.E
quip
men
t Im
prov
emen
t act
iviti
es3.
Prod
uctio
n A
uton
omou
s Mai
nten
ance
4.
Pl
anne
d M
aint
enan
ce5.
Qua
lity
Mai
nten
ance
6.Pr
oduc
t & E
quip
men
t Ini
tial C
ontr
ol7.
Edu
catio
n &
Tra
inin
g8.
Off
ice
TPM
9.Sa
fety
, Hyg
iene
& E
nvir
onm
ent
10.
Qua
ntifi
able
TPM
Mea
sure
men
t
tpm
/mos
es6
Exe
cutiv
e O
verv
iew
Of
1.A
uton
omou
s Mai
nten
ance
2.E
quip
men
t Im
prov
emen
t3.
Plan
ned
Mai
nten
ance
4.Q
ualit
y M
aint
enan
ce5.
Off
ice
TPM
tpm
/mos
es7
QU
ICK
LO
OK
AT
Prod
uctio
nA
uton
omou
s M
aint
enan
ce
tpm
/mos
es8
LOG
IC O
F A
M S
TE
PS
STE
PS
1,2
,3IM
PR
OV
E T
HE
E
QU
IPM
EN
T
U
SER
-FR
IEN
DLI
NE
SS
STE
PS
4,5
,6
IM
PR
OV
E W
OR
KE
R
KN
OW
-HO
W T
O M
AIN
TA
IN
EQ
UIP
ME
NT
TH
RO
UG
H
STR
UC
TU
RE
D S
PE
CIF
IC
SKIL
LS.
STE
P 7
FLA
TT
EN
ED
O
RG
AN
IZA
TI
ON
.
tpm
/mos
es9
Step
#St
ep G
oal
Stan
dard
sSt
ep 1
Res
tora
tion
=> 8
5% r
epai
r ra
te
Step
2El
imin
ate
Sour
ces o
f Con
tam
inat
ion
=>70
% su
cces
sful
eff
ort
Step
3Im
prov
e Eq
uipm
ent A
cces
sibi
lity
=>70
% su
cces
sful
eff
ort
Step
4In
itial
Mai
nten
ance
Sta
ndar
ds>
50%
sudd
en b
/d r
educ
tion
Step
5G
ener
al In
spec
tionS
kills
> 90
% su
dden
b/d
red
uctio
n
Step
6A
uton
omou
s Ins
pect
ion
> 95
% su
dden
b/d
red
uctio
n
Step
7O
rgan
ise
and
man
age
wor
kpla
ceT
BD
by
man
agem
ent
AM
ST
AN
DA
RD
S
tpm
/mos
es10
( Ste
p( S
tep --
1 : R
esto
ratio
n Eq
uipm
ent )
1 : R
esto
ratio
n Eq
uipm
ent )
OPE
RA
TO
RS
LE
AD
ER
MA
INT.
STA
FF
ENG
R.
STA
FF
CO
NFI
RM
ATI
ON
O
F PR
OG
RES
SD
EPT.
CH
IEF
SUPE
RV
ISO
RS
GR
OU
P LE
AD
ERLI
ST O
F EX
T/IN
TA
BN
OR
MA
LITI
ES
MEE
TIN
G T
OPL
AN
CO
UN
TER
MEA
SUR
ES
CO
UN
TER
MEA
SUR
ES
STEP
-1 A
UD
ITM
OD
EL M
AC
HIN
E
MA
INTE
NA
NC
EST
AFF
ENG
INEE
RIN
G
STA
FF
AU
TON
OM
OU
SM
AIN
TEN
AN
CE
GR
OU
P
FOLL
OW
UP
ON
AU
DIT
FEED
BA
CK
CO
UN
TER
MEA
SUR
ESEX
TEN
DED
TO
ALL
EQU
IPM
ENT
AU
DIT
DEP
T.C
HIE
F
LE
AD
ER
SUPE
RV
ISO
RS
TO N
EXT
STEP
tpm
/mos
es11
( Ste
p( S
tep --
2 : E
limin
ate
Con
tam
inat
ion
& S
tain
s on
Are
a &
Par
ts)
2 : E
limin
ate
Con
tam
inat
ion
& S
tain
s on
Are
a &
Par
ts)
Com
plet
e St
ep-1
Step
-1 S
umm
ary
resu
lts &
find
ings
Wha
t ?
Whe
re ?
How
m
uch
Why
?
AM
Tea
m=>
70%
Cou
nter
mea
sure
s
1st P
re-
Aud
itby
TPM
D
ept.
Step
-3
Pres
ent
Cou
nter
mea
sure
sto
TPM
WC
and
impl
emen
tatio
n
GM
/Spo
nsor
sA
udit
Ow
n ar
eaB
uy -
Off
tpm
/mos
es12
( ST
EP
3 :
IMP
RO
VE
EQ
UIP
ME
NT
AC
CE
SSIB
ILIT
Y )
.
AM
Lea
der
Mod
el m
/cPa
ssed
Step
2
Are
as d
iffic
ult o
rin
acce
ssib
le fo
r cl
eani
ngch
ecki
ng &
lubr
icat
ing
Inac
cess
ible
No
Plac
e T
oSt
and
Wir
ing
or p
ipin
gob
stru
ctC
anno
t see
ea
sily
Tim
e C
onsu
min
gto
cle
anT
ime
Con
sum
ing
to c
lean
Prod
uct M
anag
er
Ope
rato
r L
eade
r/ O
pera
tors
Supe
rvis
or
Mod
el M
achi
neG
oes T
o St
ep 4
Pre-
Aud
itby
TPM
Dep
t .W
/CB
uy O
ffG
MA
udit
Ow
nA
rea
Buy
Off
tpm
/mos
es13
( Ste
p 4
: Ini
tial M
aint
enan
ce S
tand
ards
)( S
tep
4 : I
nitia
l Mai
nten
ance
Sta
ndar
ds )
Mod
el m
/cpa
ssed
Step
3
Initi
alm
aint
enan
cest
anda
rd
Har
d to
lu
bric
ate
Har
d to
che
ckoi
l lev
elA
bnor
mal
ityin
lubr
icat
ion
equi
pmen
tA
bnor
mal
ityin
cir
cula
tion
of lu
bric
atio
nE
quip
men
tge
ts d
irty
duri
ng o
iling
Prod
uct M
anag
erA
M L
eade
r
Ope
rato
r L
eade
r/op
erat
orC
ount
er m
easu
re fo
r cl
eani
ng a
nd c
heck
ing
Supe
rvis
or
Dra
ft st
anda
rds
for
clea
ning
,in
spec
tion
&lu
bric
atio
nE
ngin
eer
& M
aint
enan
ce
Tri
al P
erio
dA
ttac
hid
entif
icat
ion
labe
l
Con
firm
stan
dard
for
clea
ning
,in
spec
t &lu
bric
atio
n
TPM
dep
t.Pr
e-au
dit
GM
aud
it
Prol
ifera
tion
of S
tep
4
tpm
/mos
es14
Prep
are
text
s and
dai
lysc
hedu
les/
chec
k lis
tsPr
epar
e te
xts a
nd d
aily
sche
dule
s/ch
eck
lists
( Ste
p 5
: Gen
eral
Insp
ectio
n sk
ills
)( S
tep
5 : G
ener
al In
spec
tion
skill
s )
•Lub
ricat
ion
•Equ
ipm
ent p
arts
tigh
teni
ng
•Pne
umat
ics
•Hyd
raul
ics
•Ele
ctric
al•D
rive
Syst
em•W
ater
•Fire
pre
vent
ion/
safe
ty
•Lub
ricat
ion
•Equ
ipm
ent p
arts
tigh
teni
ng
•Pne
umat
ics
•Hyd
raul
ics
•Ele
ctric
al•D
rive
Syst
em•W
ater
•Fire
pre
vent
ion/
safe
ty
sele
ct g
ener
al
insp
ectio
n ite
ms
sele
ct g
ener
al
insp
ectio
n ite
ms
Man
uals
Man
uals
Man
uals
Che
cklis
tC
heck
list
Cut
aw
aym
odel
sC
ut a
way
Cut
aw
aym
odel
sm
odel
s
Rev
ised
Mai
nten
ance
stan
dard
s
Rev
ised
Rev
ised
Mai
nten
ance
Mai
nten
ance
stan
dard
sst
anda
rds
Man
ager
s/su
perv
isor
spa
rtici
pate
in tr
aini
ngM
anag
ers/
supe
rvis
ors
parti
cipa
te in
trai
ning
Test
Test
Impl
emen
tge
nera
l Im
..
TPM
off
ice
Pre-
Aud
itTP
M o
ffic
e Pr
e-A
udit
GM
Aud
itG
M A
udit
Prol
ifera
te
Step
-5
tpm
/mos
es15
( Ste
p( S
tep --
6 : A
uton
omou
s In
spec
tion
)6
: Aut
onom
ous
Insp
ectio
n )
Mai
nten
ance
Insp
ectio
n st
anda
rds,b
reak
dow
n an
alys
is
Ope
rato
rs
who
un
ders
tand
th
eir
equi
pmen
t (a
ble
to m
aint
ain
insp
ectio
n st
anda
rds)
Step
-4St
ep-4
Dai
ly c
heck
ing,
adju
stm
ent,a
ndim
prov
emen
t of
cond
ition
s for
co
rrec
t ope
ratio
n
Dai
ly c
heck
ing,
adju
stm
ent,a
ndim
prov
emen
t of
cond
ition
s for
co
rrec
t ope
ratio
n
Step
1 to
3:
Step
1 to
3:
Esta
blis
h ba
sic
cond
ition
s(c
lean
ing
and
lubr
icat
ion)
Esta
blis
h ba
sic
cond
ition
s(c
lean
ing
and
lubr
icat
ion)
Step
-5
Rev
ise
prov
isio
nal s
tand
ards
Fina
lise
stan
dard
s for
cle
anin
g an
d lu
bric
atio
n
Inspection skill check-up
tpm
/mos
es16
Step
Step
-- 7 : 7 : O
rgan
ise
Org
anis
ean
d M
anag
e W
orkp
lace
and
Man
age
Wor
kpla
ce
Org
anis
ean
d se
t sta
ndar
ds fo
r :
EQ
UIP
ME
NT
PR
EC
ISIO
NIN
SPE
CT
ION
ITE
MS
TO
OL
S A
ND
MA
TE
RIA
LS
FLO
W A
ND
ST
OR
AG
EST
AN
DA
RD
S FO
R
IND
IVID
UA
L W
OR
KR
ESP
ON
SIB
ILIT
IES
tpm
/mos
es17
QU
ICK
LO
OK
AT
Plan
ned
Mai
nten
ance
Pi
llar
tpm
/mos
es18
GO
AL
OF
PLA
NN
ED
M
AIN
TE
NA
NC
E.
Ach
ieve
“ZE
RO E
QUI
PMEN
T BRE
AKD
OW
NS”
by im
plem
entin
g sy
stem
s of
“p
arts
repl
acem
ent b
efor
e fa
ilure
”th
roug
hTB
M a
nd C
BM.
PR
OD
UC
TIO
N
AU
TO
NO
MO
US
MA
INT
EN
AN
CE
SY
STE
M.
P.M
. ST
AN
DA
RD
S
GE
NE
RA
L IN
SPE
CT
ION
ST
DS.
+
AN
NU
AL
MA
INT
EN
AN
CE
P
LAN
S
EQ
UIP
ME
NT
TO
TA
L M
AIN
TE
NA
NC
E
STA
ND
AR
DS
tpm
/mos
es19
PLA
NN
ED
MA
INT
EN
AN
CE
A
CT
IVIT
IES :
OSU
PP
OR
T A
UT
ON
OM
OU
S M
AIN
TE
NA
NC
E A
CT
IVIT
IES
BY
TE
CH
NIC
AL
SUP
PO
RT
, BR
EA
KD
OW
N A
NA
LYSI
S A
ND
DE
MA
RC
AT
ION
BE
TW
EE
N P
RO
DU
CT
ION
& P
.M. S
YST
EM
S.
OP
-M A
NA
LYSI
S FO
R C
HR
ON
IC B
RE
AK
DO
WN
S.
OT
IME
BA
SED
MA
INT
EN
AN
CE
ITE
MS
OC
ON
DIT
ION
BA
SED
MA
INT
EN
AN
CE
ITE
MS.
OSP
AR
ES
MG
TM
& M
AIN
TE
NA
NC
E D
AY
PR
AC
TIC
E.
tpm
/mos
es20
QU
ICK
LO
OK
AT
Equ
ipm
ent
Impr
ovem
ent
Pilla
r
tpm
/mos
es21
RO
LE O
F P
LAN
T E
I TE
AM
Ach
ieve
sys
tem
atic
bre
akth
roug
hs in
eq
uipm
ents
’6 B
IG L
OSS
ES a
nd e
stab
lish
Stan
dard
s fo
r Bas
ic M
achi
ne C
ondi
tions
.
The
Basic
Mac
hine
Con
ditio
ns a
re:
1. C
lean
ing
Stan
dard
s.2.
Lub
ricat
ion
Stan
dard
s.3.
Bol
t-tig
hten
ing
Stan
dard
s.
tpm
/mos
es22
EQ
UIP
ME
NT
6 B
IG L
OSS
ES
(F
OC
US
IS A
T T
HE
BO
TT
LEN
EC
K
PR
OC
ESS
ES.
)
1. B
RE
AK
DO
WN
LO
SSE
S
2. S
PE
ED
LO
SSE
S.
3. S
ET
UP
LO
SSE
S.
4. D
EFE
CT
LO
SSE
S.
5. S
TA
RT
-UP
OR
YIE
LD L
OSS
ES
6. M
INO
R S
TO
PP
AG
ES
LOSS
ES
tpm
/mos
es23
MA
INT
LE
VE
L 1
LE
VE
L 2
LE
VE
L 3
LE
VE
L 4
• H
ave
chro
nic
B/D
s•
B/d
Rep
air
time
PM ti
me.
• >2
0% d
evia
tion
ofse
rvic
e lif
e ra
nge.
• R
oot-
caus
e s o
f bre
akdo
wn
not c
lear
.
• O
nly
spon
tane
ous
brea
kdow
ns.
• B
/d R
epai
r tim
e =
PM ti
me.
• W
ithin
par
ts s
ervi
ce li
fesp
an.
• R
oot-
caus
es o
f B/D
s are
clea
r an
d a
ddre
ssed
.
• T
ime-
base
d co
mpo
nent
mai
nt.
syst
em.
• D
/Tre
pair
time
< P
M ti
me
• B
/d d
ownt
ime
< 1%
• Se
rvic
e lif
e of
com
pone
nts
=> u
pper
ran
ge o
f spe
cs.
• C
ondi
tion-
base
d m
aint
syst
em•
Mai
nt st
aff d
o on
ly P
M.
• A
M d
o D
/T r
epai
rs <
at 0
.1%
of D
T le
vel.
• C
lear
impr
ovem
ent
in M
TB
F•
Inco
mpl
ete
setu
pdo
cum
enta
tion.
• Se
tup
times
var
iatio
n>3
0%.
• C
ompl
ete
set-
updo
cum
enta
tion
• O
n-lin
e an
d of
f-lin
e se
tups
are
defin
ed.
• Se
tupT
ime
vari
atio
n <
15%
• Su
cces
sful
eff
orts
to c
onve
rton
-line
to o
ff-li
ne se
tups
• A
ll ad
just
men
ts a
re fu
llycl
arifi
ed a
nd st
anda
rdiz
ed.
• O
ptim
al se
t-up
s und
er 1
0m
ins.
• 1s
t tim
e se
t-up
pro
duce
goo
dpa
rts.
No
need
to a
djus
t an
yfu
rthe
r.•
No
awar
enes
s/da
ta.
• D
ata
on fr
eque
ncy,
loca
tion
of m
inor
stop
page
s.•
Roo
t-ca
uses
of
m
inor
stop
page
s are
cle
ar a
ndco
unte
rmea
sure
s in
plac
e.
• Z
ero
min
or st
oppa
ges.
• E
quip
men
t spe
cs n
ot c
lear
.•
No
sett
ings
doc
umen
ted
bydi
ffer
ent p
acka
ges/
mac
hine
mod
els &
type
s.
• R
oot-
caus
es a
re c
lear
• Se
ttin
gs d
ocum
ente
d by
pack
age
/ mac
hine
type
.•
< 5%
var
iatio
n be
twee
n sa
me
type
mac
hine
s
• C
ount
erm
easu
res f
or r
oot-
caus
es o
f spe
ed lo
sses
impl
emen
ted.
• R
evis
ed se
ttin
gs w
ith n
otes
on
qual
ity a
nd a
ccur
acy
impa
ct.
• <
2%
spee
d lo
ss.
• O
pera
tes a
t des
igne
d sp
eed
orab
ove.
• Ze
ro S
peed
loss
es
• N
othi
ng d
one
abou
tch
roni
c lo
sses
.•
No
resu
lts fr
om p
revi
ous
actio
ns
• C
hron
ic d
efec
ts a
requ
antif
ied
by ty
pe, f
requ
ency
and
volu
me.
• R
oot c
ause
s for
pro
blem
s are
iden
tifie
d an
d un
ders
tood
.
• C
ount
erm
easu
res i
mpl
emen
ted
ef
fect
ive
for
earl
y in
-pro
cess
dete
ctio
n of
def
ects
.•
Q-c
ompo
nent
s ide
ntifi
ed a
ndef
fect
s on
qual
ity a
re c
lear
.
• M
-Q r
elat
ions
hip
esta
blis
hed.
• R
egul
ar a
udit
of Q
-co
mpo
nent
s•
Los
s due
to q
ualit
y de
fect
s is
< 0.
1%
LO
SSE
S
Mai
ntL
EV
EL
1.B
reak
dow
n
loss
es
2.Se
tup
Los
ses
3.M
inor
Stop
page
s
4.Sp
eed
Los
ses
5. D
efec
t &St
artu
pL
osse
s
LE
VE
L 1
•.
R
ED
UC
ED
1/2
0T
H O
F C
UR
RE
NT
LR
VR
L.
SEV
ER
ITY
OF
EQ
UIP
ME
NT
6 B
IG L
OSS
ES
tpm
/mos
es24
OV
ER
AL
L E
QU
IPM
EN
T E
FFIC
IEN
CY
OV
ER
AL
L E
QU
IPM
EN
T E
FFIC
IEN
CY
OE
E =
> 85
% ta
rget
NO
TE
: OE
E IS
NO
T T
HE
SA
ME
AS
UT
ILIZ
AT
ION
. UT
ILIZ
AT
ION
ME
ASU
RE
S T
HE
U
P-T
IME
OF
TH
E E
QU
IPM
EN
T. O
EE
M
EA
SUR
ES
TH
E ‘A
BIL
ITY
’OF
TH
E
EQ
UIP
ME
NT
TO
PR
OD
UC
E. L
IKE
TH
E H
OR
SE-
PO
WE
R R
AT
ING
OF
AN
EN
GIN
E, O
EE
D
ESC
RIB
ES
TH
E E
QU
IPM
EN
T’S
HE
ALT
H.
tpm
/mos
es25
Spor
adic
& C
hron
ic P
robl
ems
Why
-Why
P-M
Ana
lysi
s.A
naly
sis.
FOR
PR
OB
LEM
S W
ITH
CLE
AR
AN
D
ASS
IGN
AB
LE
CA
USE
S.FO
R P
RO
BLE
MS
WIT
H
CLE
AR
CA
USE
S &
NO
E
FFE
CT
IVE
CO
UN
TE
R-
ME
ASU
RE
S
tpm
/mos
es26
Why
-Why
Ana
lysi
s & P
-M A
naly
sis
•U
sed
with
oth
er d
ata
anal
ysis
or d
ata
colle
ctio
n to
ols.
•Em
phas
ize
on lo
gica
l rea
soni
ng to
fully
un
ders
tand
the
who
le c
hain
of c
ause
-eff
ects
so a
s to
dev
ise
holis
tic m
ultip
le so
lutio
ns.
•A
ll de
fect
s, br
eakd
owns
, acc
iden
ts a
nd w
ork
–pr
oble
ms a
re re
sult
of a
n er
ror b
y M
an w
hich
is
the
Roo
t Cau
se.
•Pr
oble
ms a
re tr
aced
to a
ll th
e 4M
s•
Solu
tion
Sust
aine
d by
link
ed to
the
TPM
syst
ems.
tpm
/mos
es27
Chec
ked
byPr
epar
ed b
yPh
enom
enon
Phys
ical v
iew (L
ogica
l rea
sonin
g)
PM A
nalys
is Ch
art
No1
/3Ho
oking
erro
rs oc
casio
nally
occu
r dur
ing
cont
inuou
s wind
ingDi
stanc
e betw
een t
he ro
ller a
t the t
ip of
the fly
er an
d hoo
k ne
edle
cha
durin
g hoo
king
Contr
ibuti
ng
Cond
ition
Inve
stiga
tion
Resu
lt4 M
Cor
relat
ion,
First
Item
In
vesti
gatio
n Re
sult
4M C
orrel
ation
, Se
cond
Item
Inves
tigat
ion/
Inve
stiga
tion
Resu
ltIf
NG,
Cou
nterm
easu
reRe
s
Inve
stigat
ion
Mea
surin
g Met
hod
Tem
pora
ry
Decis
ion
Crite
rion
Mea
sure
- m
ent
Valu
eD
ecisio
nIn
vesti
gatio
n/ Me
asuri
ng
Meth
od
Tem
pora
ry
Decis
ion
Crite
rion
Mea
sure
- me
nt V
alue
Deci
sion
(3rd
, 4th
, 5th
an
d 6th
Item
sM
easu
ring
Meth
od
Tem
pora
ry
Decis
ion
Crite
rion
Mea
sure
- me
nt V
alue
Deci
sion
why N
G?Re
stora
tion,
Rep
lace -
m
ent,
Impr
ovem
ent,
Remo
delin
g
Meas
urem
ent
Value
1. Po
sitio
n at w
hich
170º
to 18
0º10
6º to
180º
NG1-
1 Fly
er ro
tatio
n is
1to 1
5kg/
cm²
20 kg
/cm²
NG
1-1-1
.Te
nsion
Gau
ge12
0g to
150
g17
0g to
300
gNG
Carb
on p
owde
rsCl
ean
120g
to 15
0g
ro
ller a
tip
of
not s
moo
th w
hen
load
Carb
on co
ntact
cont
actfro
m a
depo
sit
fl
yer s
tops
is no
t app
lied.
pres
sure o
f the
sur
face
insid
e brus
h box
.
ch
ange
s.sli
de ri
ng is
high
. ·Sp
ring d
iffere
ntRe
place
with
14
0g
fro
m th
ose in
othe
rth
e sam
e spr
ing
18
0°pla
ces w
as us
ed.
(1/8 p
lace)
90°
270°
carb
on
s
lide r
ing
1-1-
2 Gall
ing o
f To
uch by
han
dSm
ooth
with
Smoo
thOK
0
°sp
indle
beari
ng.
no r
ough
ness
1-1-3
. V-be
ltPu
sh-p
ull ga
uge
Amo
unt o
fA
djust
ment
was m
ade b
y·A
djust
amou
nt o
f belt
10m
m/1
kg c
m
tensio
n is h
igh.
defle
ction
2 to
3 m
m /
turn
ing
the b
elt a
nd
defl
ection
.
10m
m/1k
g cm²
1 kg
cm²
NG
touc
hing
it by
hand
.
1-1-
4. M
otor
Thick
ness
gaug
e0.
1 to
0.3m
m0.
1 to
0.6m
mN
G·Pl
ate
sprin
g of
·Rep
lace
0.25m
m
brake
pad
brak
e di
sc d
amag
ed
clear
ance
1-1-
5 Mot
orTh
ickne
ss ga
uge
0.1
to 0
.3mm
1. 0.
25mm
OK
clutch
plat
e 2.
0.3m
mOK
cleara
ncin
g of
3. 0.
3 mm
OK
brak
e disc
dama
ged.
1-1-6
.Di
al ga
uge
Below
0.05
0.03m
mOK
Spin
dle sh
aft
defle
ction
tpm
/mos
es28
QU
ICK
LO
OK
AT
Qua
lity
Mai
nten
ance
Pi
llar
tpm
/mos
es29
QU
ALI
TY
M
AIN
TE
NA
NC
E:
IS A
CT
IVIT
IES
TO
SE
T E
QU
IPM
EN
T C
ON
DIT
ION
S,B
ASE
D O
N T
HE
BA
SIC
CO
NC
EP
T O
F M
AIN
TA
ININ
G
PE
RFE
CT
EQ
UIP
ME
NT
TO
MA
INT
AIN
PE
RFE
CT
Q
UA
LIT
Y O
F P
RO
CE
SSE
D G
OO
DS.
TH
E M
AC
HIN
E
CO
ND
ITIO
NS
(Q-C
OM
PO
NE
NT
S)A
RE
CH
EC
KE
D A
ND
M
EA
SUR
ED
IN T
IME
-SE
RIE
S T
O V
ER
IFY
TH
AT
M
EA
SUR
ED
VA
LUE
S A
RE
WIT
HIN
ST
AN
DA
RD
V
ALU
ES
TO
PR
EV
EN
T D
EFE
CT
S. T
HE
TR
AN
SIT
ION
OF
ME
ASU
RE
D V
ALU
ES
IS W
AT
CH
ED
TO
PR
ED
ICT
P
OSS
IBIL
ITIE
S O
F D
EFE
CT
SO
CC
UR
RIN
G A
ND
TO
T
AK
E C
OU
NT
ER
ME
ASU
RE
S B
EFO
RE
HA
ND
tpm
/mos
es30
1. Id
entif
y al
l the
Q-c
ompo
nent
s 2.
Impl
emen
t foo
l-pro
ofin
g te
chni
ques
topr
even
t man
and
mat
eria
ls-c
ause
d de
fect
s.3.
Elim
inat
e al
l Chr
onic
def
ects
.
RO
LE O
F P
LAN
T T
PM
-QM
Ach
ieve
“ZE
RO D
EFEC
T”by
ide
ntify
ing
all t
he
upst
ream
fact
ors
of E
quip
men
t cau
ses
of d
efec
tsan
d im
plem
entin
g fo
ol-p
roof
ing
tech
niqu
es to
elim
inat
e m
an a
nd m
ater
ials-
caus
ed d
efec
ts.
tpm
/mos
es31
C
oppe
r Bru
sh, F
lippe
r Spr
ing
a
nd B
rass
Bar
.
Plat
ing C
hem
ical
D
ryer
Hea
ter
C
orne
r Spr
ay a
nd R
insing
Wat
er
Dry
er B
low
er
Part
of M
achi
neP
latin
g C
hem
ical
Flip
per
B. B
ar /
C. B
rush
Dry
er H
eate
r
Mea
sure
men
tC
hem
ical
Con
tent
Tens
ion
Con
tact
Pre
ssur
eH
ot A
ir Te
mpe
ratu
re
Std
. Val
ueM
SA
: 37.
5% +
/- 5%
Upp
er <
= 25
0 g
Upp
er =
6 k
g/cm
Upp
er =
130
deg
. CTI
N: 3
7.5
g/l +
/- 5
g/l
Nom
inal
= 1
20g
Nom
inal
= 5
.5 k
g/cm
Nom
inal
= 1
25 d
eg C
Add
itive
: 2 g
/l +/
- 0.5
g/lL
ower
=>
60g
Low
er =
5 k
g/cm
Low
er =
> 12
0 de
g C
Inte
rval
Dai
lyW
eekl
yFo
rthni
ghtly
Dai
ly
Q
ualit
y D
efec
tT
hick
ness
Fai
lT
hick
ness
Fai
lT
hick
ness
Fai
lT
hick
ness
Fai
lQ
ualit
y of
M/c
Par
t
Circ
ular
ity
Con
tent
Det
erio
ratio
n
Sm
ooth
ness
Q-T
ag n
um
ber
& R
evis
ion
Q-t
ag #
60-
001
Rev
AQ
-tag
# 6
0-00
2 R
ev A
Q-t
ag #
60-
003
Rev
AQ
-tag
# 6
0-00
4 R
ev A
910
1112
13
12
3
45
67
814
EX
AM
PLE
OF
AN
M-Q
(MA
CH
INE
-QU
ALI
TY
) M
AT
RIX
tpm
/mos
es32
AB
OU
T O
FFIC
E T
PM•
Is a
stru
ctur
ed 5
S pr
ogra
m u
sing
Why
-Why
A
naly
sis a
s a p
robl
em-s
olvi
ng to
ol.
•H
as si
mila
r A
uton
omou
s Mai
nten
ance
5 S
teps
•Im
prov
es “
CR
ITIC
AL
FU
NC
TIO
NS”
of
War
e-ho
use,
Sto
rage
Pla
ce, a
dmin
istr
ativ
e ar
eas’
thro
ugh
wor
k-flo
w st
udie
s.•
Are
as c
ontr
ibut
ing
to O
EE
loss
es a
re se
lect
ed
for
Kai
’zen
activ
ities
.
tpm
/mos
es33
The
5S
step
-by-
step
pro
gram
.1
-Cle
anin
g &
Res
tora
tion.
2 -E
limin
ate
Stai
ns, M
ixed
,C
onta
min
atio
n.
3 -I
mpr
ove
Acc
essi
bilit
y.
4 –
Stan
dard
izat
ion
&
Con
trol
of W
ork.
5 -S
elf M
anag
emen
t
TH
OR
OU
GH
LY R
EST
OR
E &
CLE
AN
.
MO
TIV
AT
ION
TH
RO
UG
H
PA
RT
ICIP
AT
ION
.ST
UD
Y R
OO
T C
AU
SES
OF
DIR
T,
MIX
ING
,
LOSS
, DA
MA
GE
AN
D T
AK
E A
CT
ION
S.A
CH
IEV
E 1
MIN
UT
E A
CC
ESS
IBIL
ITY
T
IME
FO
R D
OC
UM
EN
TS
+ P
AR
TS.
IM
PLE
ME
NT
ST
OC
K-M
AN
AG
EM
EN
T-
AT
1 G
LAN
CE
.A
CH
IEV
E A
PR
OB
LEM
-FR
EE
WO
RK
FL
OW
IN S
TO
CK
INV
EN
TO
RY
, DA
TA
A
VA
ILA
BIL
ITY
.SE
LF M
AN
AG
ING
WO
RK
TE
AM
S.
tpm
/mos
es34
TPM
JIPM
,
TO
GE
TH
ER
......
Tow
ards
Wor
ld-C
lass
Man
ufac
turi
ng E
xcel
lenc
e
tpm
/mos
es35
DE
VE
LO
PME
NT
PRO
GR
AM
DE
SCR
IPT
ION
INT
RO
DU
CT
OR
Y S
TA
GE
2001
PRA
CT
ICE
ST
AG
E20
02C
ON
SOL
IDA
TIO
N S
TA
GE
2003
2004
FIN
AL
ST
AG
EJI
PM A
WA
RD
Polic
yB
asic
Obj
ectiv
ePr
olife
ratio
n an
d to
tal i
nvol
vem
ent
Def
ects
and
bre
akdo
wns
pre
vent
ion
Zero
def
ects
and
zer
o br
eakd
owns
thro
ugh
ever
y em
ploy
ees’
invo
lvem
ent
Cha
lleng
e th
e st
anda
rds
Bas
ic T
PMW
eekl
y W
C m
tgs
Org
anis
atio
n &
Reg
ular
EI m
tgs
Mai
n C
omm
ittee
sR
egul
ar P
M m
tgs
Bas
ic S
trate
gySe
lect
Mod
el m
achi
ne, f
orm
Tea
ms,
Impl
emen
t im
prov
emen
ts o
n M
odel
M/C
s &th
en p
rolif
erat
e to
all
sim
iliar
equi
pmen
tsto
ach
ieve
a sk
illed
wor
kfor
ce a
nd e
quip
men
t tha
t do
not b
reak
dow
n.
Empl
oyee
Sugg
estio
n Sc
hem
efo
r Con
tinou
sIm
porv
emen
t
Polic
y
Pilo
t Are
a
Prol
ifera
te
TPM
Mea
sure
men
tsO
EE/ B
reak
dow
ns/ Q
ualit
y
Aut
onom
ous
Mai
nten
ance
(5 P
ilot L
ines
then
85%
of r
est o
f typ
esof
equ
ipm
ent)
Step
1: R
esto
ratio
nSt
ep 2
: El
imin
ate
Con
tam
inat
ion
Step
3 :
Impr
ove
Acc
essi
bilit
ySt
ep 4
: In
itial
Sta
ndar
ds-P
repa
re In
spec
tion
man
uals
Step
5 :
Gen
eral
Insp
ectio
nSt
ep 6
: A
uton
omou
s Ins
pect
ion
Step
7 :
Man
age
qual
ity o
f wor
k
• Te
chni
cal O
pera
tors
• O
EE =
> 85
%
Eqip
men
tIm
prov
emen
tson
6 lo
sses
Tech
nica
l sup
port
for A
MB
asel
ine
curr
ent m
/c lo
sses
Mod
el m
/c b
asic
con
ditio
nsM
odel
m/c
loss
es im
prov
emen
ts
PM &
QM
Syst
ems
Plan
ned
mai
nten
ance
sche
dule
s(T
ime
& c
ondi
tion
base
d)M
achi
ne/P
rodc
utQ
ualit
y m
atrix
TPM
Tra
inin
g an
dSk
ills
Dev
elop
men
t
AM
Ski
lls w
orks
hops
PM A
naly
sis w
orks
hops
Adv
ance
d w
orks
hops
Early
Equ
ipm
ent &
Prod
uct C
ontro
l
Dev
elop
trou
ble
prev
entio
nch
eckl
ists
on
Off
ice
TPM
5S P
rogr
am fo
r off
ice
Safe
ty, H
ygie
ne &
Envi
ronm
ent
Equi
pmen
t Saf
ety
Wor
kpla
ce e
nviro
nmen
t & w
aste
treat
men
t
Pilo
t M/c
sR
est o
f M/c
s
(Lub
ricat
ion
& b
oltin
g)
Step
1
Step
2St
ep 3
Step
4St
ep 5
Step
6St
ep 7
12
34
56
7m
anua
lsm
anua
ls
{Tec
h. O
prSt
anda
rds}
Step
5 :
Gen
eral
Insp
ectio
n Sk
ills
5.1
B
olts
, Nut
s, Lu
bric
atio
n5.
2
Pnue
mat
ics
5.3
El
ectri
city
& M
otor
s5.
4
Oil
Hyd
raul
ics
5.5
Pa
rtici
pate
in in
-line
repa
irs
Ana
lysi
s
C
ontro
l Sta
ndar
ds
Q
ualit
y m
atrix
es
Esta
blis
h sy
stem
s & sc
hedu
les
Impl
emen
t
Impl
emen
t
Esta
blis
hIm
plem
ent
Dev
elop
Impl
emen
t on
test
run
Rev
iew
Enha
nce
Rev
iew
Enha
nce
TPM
MA
STE
RPL
AN
200
1 -2
003
tpm
/mos
es36
TH
AN
K
YO
U
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