The Lean EnterpriseThe Lean Enterprise Introduction to TPM Total Productive MaintenanceLean Foundations Continuous Improvement Trainingfreeleansite.comLearning Objectives Learning ObjectivesLearn the basic philosophy of TPMExplain OEE and how it contributes to a TPM project, explore OEE components; define and calculate OEEList 6 major components of equipment lossReview and adopt the 7 steps to Autonomous Maintenancefreeleansite.comTPM The NeedTPM The NeedProcess Industry relies heavily on equipment that is integrated and runs continuouslyWhen down, losses are costlyWith lower inventories, machines need to be reliableMachining and Assembly industries becoming more mechanized to save manpower and do difficult jobs More machines to maintain Need to save energyfreeleansite.comTPM The PhilosophyTPM The PhilosophyTPM aims at using equipment to its maximum and aids in reducing Life Cycle Costs (LCC)In other words - going all out to eliminate the Losses (Waste) caused by the equipmentTPM improves work activities that deal with Equipment Set-up, Operating parameters, Maintenance, Tear down, Repairs and BreakdownsIt specifically aims at the complete elimination of the six major losses while striving for a goal of zero unscheduled downtimefreeleansite.comTPM - The Six Major Losses (Waste)TPM - The Six Major Losses (Waste)Downtime Losses (1) Equipment failures (2) Set-up and adjustments Speed Losses (3) Idling and minor stoppages (4) Reduced speed (actual operating vs. designed) Defect Losses (5) Defects in process (6) Reduced yield between start ofproduction and stable productionfreeleansite.comOEE FormulasOEE Formulas1. Unexpected Eq. Breakdown2. Set-up Practice Set-ups Modify Equipment for easier checking and to eliminate sources for debris and contamination Guards Chip removal Acrylic covers to see V - belts and moving partsfreeleansite.com7 Steps to Autonomous Maintenance7 Steps to Autonomous MaintenanceStep 3 Standards FormulationStandards for clean-up and checking What equipment should be cleaned and checked? What points should be checked? Who should check? What check sheet should be used? How to react to changes.Standards are to capture what has been learnedin steps 1 and 2freeleansite.com7 Steps to Autonomous Maintenance7 Steps to Autonomous MaintenanceStep 4 Overall Checkup (Internal)Leaders (1st line Supervisors) trained Hydraulics Air Pressure Electrical/ Electronics Lubrication MechanicalOne point lessons developed (Visual Management) Team up Engineers, Maintenance, and Operators Tear down equipment Analyze defects Present findingsfreeleansite.com7 Steps to Autonomous Maintenance7 Steps to Autonomous MaintenanceStep 5 Autonomous CheckupDevelop Standards for routine internal checkup Hydraulics Air Pressure Electrical/ Electronics Lubrication MechanicalOperator executes routine checksfreeleansite.com7 Steps to Autonomous Maintenance7 Steps to Autonomous MaintenanceStep 6 Orderliness and TidinessImprove on Supplier Activity Spare parts supply partners Spare parts stores Spare parts inventoryImprove on Tool Activity Tool Crib orderliness Tools frequently used at work station(refer to Visual Management/ Visual Control)freeleansite.com7 Steps to Autonomous Maintenance7 Steps to Autonomous Maintenance Step 7 “All out” Autonomous ManagementProcess never ends Metrics AuditsEach process post Result* (actual) against Goal (target) Zero lost time accidents Zero Defects Zero Breakdowns Zero set-up time or at least 10 minutesPractice Quick Changeovers/ SMED (see separate module)* Utilize Accountability Meetings (see separate module)freeleansite.comTPM Kaizen and Reliability MaintenanceTPM Kaizen and Reliability MaintenanceKAIZEN (see separate module) SWAT Team approach to major problems(Focus improvement effort around 6 big Losses)Reduction in Changeover/ Set-up timeRELIABILITY Driven by Pareto Analysis to prioritize Data based Reduction in MTTR Increase in MTBFfreeleansite.comReliability MaintenanceReliability MaintenanceMeantime to Failure (Goal is to maximize) Machine Breakdown Tool Breakdown Part Failure Meantime to Repair (Goal is to minimize) Diagnose problem Correct problem Set up Machine to make good parts Spare parts control Analyze using Statistical Tools Reliability Measures Problem Solving Tools Vibration Analysis Toolsfreeleansite.comTPM - Reliability Kaizen ExamplesTPM - Reliability Kaizen Examples1) Tool cutting Tip (Nissan Motors) Life Cycle = 45 piecesKAIZEN #1 Vibrational analysis to optimize rotational speed. Life cycle = 132 pieces. KAIZEN #2 Analysis of wear pattern to optimize tool geometry. Life cycle = 305 pieces.2) Tool cutting (Toyota Motors) Tool expensive and takes long time to set upKAIZEN #1 Reduced set-up time from 15 minutes to less than 10 seconds. KAIZEN #2 Studied correlation between life of tool and number of cuts between sharpening