45723260 t4s4 successfully deploying total productive maintenance

Successfully Deploying Total Productive Maintenance

Track 4 Session 4

2 0 0 7 M A T E R I A L H A N D L I N G & L O G I S T I C S C O N F E R E N C E S P O N S O R E D B Y H K S Y S T E M S

Copyright 2007 © Productivity, Inc. All rights reserved

Eric D. WhitleyManufacturing Consultant

Productivity, [email protected]

800.966.5423

mailto:[email protected]



AbstractThis practical tutorial can help you make impressive gains in maintenance effectiveness by applying the principles of Total Productive Maintenance. The goal of the TPM program is to markedly increase production while, at the same time, increasing employee morale and job satisfaction. Regardless of your current strategy, the examples and approaches discussed will further your success toward system reliability.



AgendaIntroduction to TPM (Total Productive Maintenance)Review the Five Pillars of TPMUnderstand the Need For Autonomous Maintenance.Takeaways & Questions



Introduction to TPM



What Is TPM?TPM is a plant improvement methodology which enables continuous and rapid improvement of the manufacturing process through the use of employee involvement, employee empowerment, and closed-loop measurement of results.Nakajima, TPM Development Program: Implementing Total Productive Maintenance, Productivity Press

Definition:– A companywide management philosophy, supported by

interlocking developmental strategies, to maximize equipment effectiveness and eliminate equipment-related waste



MAINTENANCE –vs-“FIX/REPAIR”

Is maintenance value adding or non-value adding?

What does maintenance produce that is MORE valuable to you than the product itself?



Characteristics of TPMOptimum relationships between people and equipment

Involvement of everyone, from top leadership to shop floor workers

A cross-functional approach, involving all departments

Implementation through small group teamwork



Perfect Quality

TQMQuality at the Source

World Class Competitiveness

Minimum Lead Time

JITWaste Elimination

Product/Service

People

EquipmentProcess

Management

Sustained Profitability & Customer Delight

Lean Management SystemsContinuous Improvement

Optimal Creativity and Utilization

Teamwork100% Participation in Improvement

Optimal Effectiveness

TPMMaintenance at the Source



TPM Is a Paradigm ShiftOld Attitude

“I operate, you fix”“I fix, you design”“I design, you operate”

TPM Attitude“We are allresponsible for ourequipment, ourplant, and ourfuture”



The Old Way vs. the New WayEngineers and managers are experts; workers serve their dictates

Cost reduction comes by driving labor out of the product and increasing machine utilization

“Quick and dirty” often has to be good enough

Workers are experts; managers and engineers serve them

Cost reduction comes by speeding the product through the factory without waste

Do it right the first time — you don’t have time to do it over



Six Major Losses toEquipment Effectiveness

Failures

Setup/changeover and adjustments

Idling and minor stoppages

Reduced speed

Defects and rework

Startup loss



The Zero-Failure Principle

Hidden abnormalities

FAILURES

Wear, play, slackness, leakage, dust, dirt, corrosion,

deformation, adherence of raw materials, surface damage, cracking,

overheating, vibration, noise, and other abnormalities

A failure is the tip of the iceberg!

Expose hidden abnormalities and

prevent quality and functional failures

before they happen



The Five TPM Pillars

Training andSkill Development

EarlyEquipment

Management/MaintenancePrevention

Design AutonomousMaintenance

MaintenanceProcess

Improvement

SystematicEquipment

Improvement

TEAMS



Autonomous Maintenance



What is Autonomous Maintenance?

The ability of the machine operator to perform daily tasks to help with maintaining the production equipment.The education of the operator with respect to the functions and systems of the production machinery.The release of daily tasks from maintenance department, giving them the ability to focus on more proactive maintenance measures.



The 7 Steps of Autonomous Maintenance

Initial cleaning and inspectionEliminate contaminationEstablish provisional standardsDevelop and train inspection standardsInspect regularly and improve proceduresWorkplace managementParticipate in advanced improvement activities



A View of Equipment Losses

Lost availability, performance, and quality

Equipment poorly designed, maintained, or managed

Slight abnormalities

Sporadic lossesChronic losses

Unnoticed or ignored

Deterioration



Baby Gators Are Virtually Harmless



The gator is/was 18' 2" long.



Case StudyOrganization: Major Manufacturer of Industrial and Communications Wire and Cable.– Project Duration: >1 year; 3 Facilities.– Client Project Objectives: Diffuse company-wide

Autonomous Maintenance effort and – internal Trainer Certification.

Major Events: – 4 TPM Leadership Training Workshops.– Facilitated >16 kaizen events.– >150 employees Trained in Autonomous Maintenance.– 4 Certified Autonomous Maintenance Trainers.



Case StudyAggregate Audited Outcomes: Facility specific include: Mean-time between failures– (MTBB) improved 48%, OEE from 48% to 55%,

wire breaks @ 5 per shift reduced– to 3 breaks in 3 months, numerous equipment

redesign projects. On-going project.



Case StudyOrganization: Large Chemical Mining Operation– Project Duration: 2.5 years. On-going.– Client Project Objectives: Stabilize and Reduce

Maintenance Related Cost. Improve– Production Out-put.

Major Events: – TPM Action Planning– Implement TPM/AM– Train-the-trainer – 4 trainers certified



Case StudyAggregate Audited Outcomes: Maintenance Cost Stabilized. Production Output– Improved by 37%. $1.6M in Product Leaks

Eliminated (Documented Savings).– “Boil-outs”- Before 1 every 4 days Now 1 every

17 days.



Key TakeawaysTPM is a plant improvement process that includes everyone.The maintenance process should add value.Poor equipment performance will hinder material flow.Start by implementing Autonomous Maintenance.



Roadmap



Resourceswww.productivityinc.com

www.productivitypress.com

Autonomous Maintenance for Operators– Author, Japan Institute of Plant Maintenance

TPM Development Program : Implementing Total Productive Maintenance– Author, Seiichi Nakajima

Introduction to TPM – Total Productive Maintenance– Author, Seiichi Nakajima

http://www.productivityinc.com/

http://www.productivitypress.com/

Questions?

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