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TPM the Effective Maintenance
(23/30Apr2016)For: Kotak Malaysia (KOM) Sdn Bhd11-12 Jln Usaha 4, Kawasan Perindustrian, 75450,Ayer Keroh, Melaka Darul Azim. Presented by: Timothy WooiITS Management Sdn Bhd
05/01/20232
TPM the Effective Maintenance
TPM Implementation after (AM) & Maintenance
Workshop ActivitiesReview & extract Equipment PM to a ‘Do Dot’ Visual Master Plan & Visual TPM Board.
Attacking 6 big losses of Equipment (PdM) with Engineering Kaizen to maximize Equipment Utilization Quality, Engineering & Maintenance Kaizen Improvement Action Projects & Action Plans
Day 2. Course Content
TPM the Effective Maintenance
Maintenance and Reliability is a core business strategy. The key to a successful TPM implementation is Top Management support.
To implement TPM successfully, a 12 steps approach is used. This will lead you to the road to:“ zero breakdowns” and “zero defects’’
Course Overview
TPM the Effective Maintenance
To enable Participants understand TPM, after that to Plan, Develop, Implement and oversee the Maintenance program towards a Zero downtime by;
Course Objective
TPM the Effective Maintenance
executing Equipment Maintenance timely per schedule and reduce Company’s resources efficiently using ‘low cost or no cost’ techniques as practiced in a Lean and World class Environment.
05/01/20236
What does Maintenance mean
to you?
With TPM the focus of maintenance shifts from that of repairing, or reacting to failures to that of maintaining assets and preventing failures andquality defects in the first place.
TPM the Effective Maintenance
The root word of maintenance is Maintain,
more often than not maintenance is looked at as the people that repair
our equipment when it breaks.
Maintenance Operations
TPMSafety and Environmental
Training and Education
AutonomousMaintenanceAutonomousMaintenance Workshops
PlannedMaintenance
Moving from reactive to proactive
maintenance
Attack SixBig Losses
•Equipment failures•Setup and Adjustment•Idling and minor stoppages•Reduced speed•Defects and rework (quality)•Start up losses (reduced yield)
New assets meet production needs and minimize Life Cycle Costs (LCC)
Early EquipmentDesign and
Start upManagement
TPM the Effective Maintenance
to Extend life span of Equipment and Tools preventing damages caused by neglect and to cut cost of new Equipment reinvestment.
TPM the Effective Maintenance
to improve Productivity and Quality leading to Increased Profit by eliminating unplanned breakdowns and costly downtime.
Failure
PurchasedCondition
ImprovedCondition
Life Cycle Time
Failure
Everyone Stakeholders
Improved Asset Condition
Forced Deterioration
Equipment Failure
TPM Team Based Action
Natural Deterioration
05/01/202310
Where do we want to be?
TPM teaches to plan ahead by preventing equipment failures and quality defects before they occur.
TPM the Effective Maintenance
3P Maintenance TPM after AM(Plan, Preventive & Predictive)
Step 9: Re access planned or preventive maintenance program. Create a schedule for preventive maintenance on each piece of equipment.
Step 10: Conduct training to improve operation and maintenance skills. Maintenance department will take on the role of teachers and guides to provide training, advice, and equipment information to the teams.
Step 11: Develop an early equipment management program. Apply preventive maintenance principles during the design process of equipment.
Step 12: Continuous Improvement - As in any Lean initiative the organization needs to develop a continuous improvement mindset.
The main TPM kick-off should take the form of a formal presentation with all the employees attending.
TPM Implementation after AM5.5. TPM kick-off
This opportunity can be used to gain the full support of the employeesInvite external customers, affiliated and subcontracting companies
TPM the Effective Maintenance
*5. TPM Implementation
12 steps
Preparation
Kick-off
Implementation
Announcement to introduce TPMIntroductory education campaign for the workforceTPM Promotion (special committees)Establish basic TPM policies and goalsPreparation and Formulation of a master plan
Develop an equipment management programDevelop a planned maintenance programDevelop an autonomous maintenance programIncrease skills of production and maintenance personnel
Perfect TPM implementation and raise TPM levelsStabilizationDevelop early equipment management program
Invite customers, affiliated companies and subcontractors
Stages of successful TPM Implementation
TPM Implementation 5.6. Develop a AM Program
A handing-over of maintenance tasks from specialized maintenance personnel to production operators
Promote the 7 stepsTasks to hand overcleaning lubricating inspectingset-up and adjustment
14
=
Establish aBaseline
EnergyAwareness
Cleaning is Inspecting
EliminatingContamination
VisualManagement
EquipmentMaintenance
EquipmentLubrication Consumables
Total Productive Maintenance
A master plan lays out your goals, what you will do to achieve them and when you will achieve them.
Detailed plans for each pillar have to be prepared
TPM Implementation after AMPreparation and Formulation of a master plan
TPM the Effective Maintenance
Determining PM frequencies and how to schedule PM : Time-based or usage-based scheduling How to measure PM effectiveness and results How to measure and analyze downtime and downtime trends
How to Develop and Install a Good PM System -Do Dot Visual Master Plan & TPM Board
Maximizing Equipment Utilization –Attacking the 6 Big loses
Engineering TPM Kaizen -Improvement Projects to address risk of breakdown - 10 Steps to Improvement Action Plan
TPM the Effective Maintenance Workshop Activities
TPM Implementation after AM5.7 Develop an equipment management program
Form project teamsSelect a base line (model equipment)*identify equipment problems*analyze equipment problems*develop solutions and proposals for improvement
The tools of Total Quality Management and Continuous Improvement are applied to the management and improvement of equipment
TPM the Effective Maintenance
05/01/202318
Equipment /Tool Lubrication
The goal is to:Provide guidance in identifying and developing lubrication requirements, routes, and visual cues for the proper lubrication of equipment.
EquipmentLubrication
19
70% of all mechanical equipment failures are a result of improper
lubrication.
Too much lubricant is as bad as too little
SSSSS
Equipment LubricationSSSSS
TPM the Effective Maintenance
TPM Implementation5.8. Develop a planned maintenance program
Set up plans and schedules to carry out work on equipment before it breaks down, in order to extend the life of the equipment
Include Preventive and Predictive Maintenance
Include management of spare parts and tools
05/01/202321
Equipment /Tool MaintenanceThe goal is to:
Have a routine schedule of activities for maintaining the asset in a highly reliable condition.
Pull together all the processes and tasks developed in previous modules relating to maintenance of the equipment. Ensure PMs are up to date. If PMs are not available, they should be created for this equipment.
EquipmentMaintenance
Work with Reliability Team to install condition-based monitoring devices.
22
Tool Maintenance Example Tool Maintenance
Call for vibration check whenHour Meter reads 250
Pull Bearing Packs and Inspect when Hour meter reads 4000
Call for oil analysis whenHour Meter reads 2000
216
93
1394
Spindle #1
Servos
Power On
Hrs
Hrs
Hrs
Example: Condition-based monitoring devices.
TPM the Effective Maintenance
05/01/202324
Consumables
The goal is to:
Develop a list of consumable items needed for the routine maintenance of your equipment. Have a Parts Change History record.
Establish minimum and maximum quantities, identify standard storage locations at point of use, and apply visual management.
Consumables
Components of a Well-organized P/PdM Program Equipment inventory/numbering system Critical Spare parts inventory/forecast Sequence of tasks (PM and PdM routes) Machine maintenance critical spares
Critical spares for water jet cutter machineItem P/N
1Hi pressure seal kit 001198-12Low pressure seal kit 010641-1
3Mixing tube
010460-40-30
4Orifice assembly 014201-105Repair kit on/off valve 010200-16Swivel assy single axis 010140-17Cutting head assy8Repair kit 3/8 swivel 007117-19Pressure valve control
Example Critical
Spare List
Parts changed history for each machine/equipment( source of data: finance department based on PO for period from Jan 02 to 29 Jun 04)Equipment Name:Asset No.:
Location:
Data of purchase:
Date Part change Part no. Description RM/unit qty changed Total RM
ConsumablesConsumablesHow to keep an effective and useful equipment history
PdM Implementation5.11. Develop early equipment mgmt. program On existing machines:
Analyze historical records fortrends of types of failuresfrequency of component failuresroot causes of failures
Determine how to eliminate the problem and reduce maintenance through an equipment design change or by changing the process
TPM the Effective Maintenance
TPM principles Increase Overall Equipment Effectiveness (OEE) Improve existing planned maintenance systems The operator is the best condition monitor Provide training to upgrade operations and maintenance skills Involve everyone and utilize cross-functional teamwork
TPM the Effective Maintenance
Maximizing Equipment Utilization –Attacking the 6 Big loses
TPM the Effective Maintenance
Set-Up and Adjustment
Idling andMinor Stoppage Reduced
Speed
Quality:Defects in Process& Rework
Reduced Yield
EquipmentFailures
Easy to measure Low Impact on Profit
Highimpacton profits
Labor Materials/spares Outside servicesMaintenance overhead
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Failures
DefectsSetup and
Minor Stoppage
Reduced
Equipment ReducedYield
in ProcessAdjustment
Idling and
Speed
Availability Efficiency Quality
+ + +
Overall Equipment Effectiveness
X X
OEE is an internationally accepted measure of equipment effectiveness during planned production.It measures how effective equipment is at adding value to the manufacturing process.
05/01/202331
Attacking the Six Big Losses for OEE(Overall Equipment Effectiveness)
To achieve World class OEE Availability > 90% Efficiency > 95% Quality > 99% 90 x 95 x 99 = 85% OEE(Most companies find their OEE at 40 – 50% before TPM)
World class OEE is 85%
TPM the Effective Maintenance
Equipment Usage
EffectiveProduction
Setup&Adjustment
Equipment
FailuresDefects
Idling &
Stoppages
Reduced
Speed
Value AddedSt
artu
p los
ses &
Re
duce
d Yi
eld
TPM the Effective Maintenance
(Most companies find their Value added Equipment usage to be only at 40 – 50% before TPM)
05/01/202333
The Neglect Cycle
Human Neglect
Forced Deterioration
MinorDefects
Frustration
Losses
#1 Cause of equipment failures
TPM the Effective Maintenance
If you asked a Japanese person from a World Class manufacturing company what maintenance means they would probably say:
Maintenance means maintaining and improving the integrity of our production and quality systems through the machines, processes and people who add value to our products and services.
TPM the Effective Maintenance
Failure
PurchasedCondition
ImprovedCondition
Life Cycle Time
Failure
Everyone Stakeholders
Improved Asset Condition
Forced Deterioration
Equipment Failure
TPM Team Based Action
Natural Deterioration
PM
PMPM
PMPM
PMPM
PM
TPM the Effective Maintenance
Workshop Activities
This Workshop is designed to equip Maintenance Personal with knowledge of Maintenance TPM after A M to:
Focus on the Equipment Maintenance using ‘Do Dot’ Visual Master Plan Check sheet.
Ensure timely execution of (PM) with Production and Management support
Execute (PdM) with Engineering support to ensure Equipment are are always in a ‘ready to use’ condition ‘every time’ towards a ‘Zero Downtime’ as the Goal.
Overview
05/01/202337
Steps to Implement Planned Maintenance(Equipment /Tool Model)
1) Evaluate the current condition of the equipment
2) Improve the conditions to what they should be
3) Evaluate or prepare Preventive Maintenance inspection standards
4) Implement Proactive maintenance to extend service life
5) Improve Inspection and Maintenance efficiency
6) Implement Quality Maintenance
7) Implement CBM
05/01/202338
How to Implement Maintenance TPM -3P (Plan, Preventive & Predictive)
Maintenance Workshop
Review Maintenance TPM-Analyze existing Equipment condition and set SMART goals.(Choose 1 Equipment first).Example:-………………………………
Revisit Preventive Maintenance Checklist & effectiveness of Execution.TPM kick-off.. & TPM Board 12 Steps to TPM Installation (after step 8 )
How to Develop and Install a Good PM System
Maintenance Workshop
Do Dot Visual Master Plan &
TPM Board
Do Dot Visual Master Plan sampleMaintenance
WorkshopCritical Consumerable Spares Re-stocking Plan Date:31-May-06( Source of data: Spare parts changed from Jan 04 to May 06 based on Avialability vs Lead time)
Equipment Name: Gerber Kit cut Asset No:
No Part Part Source & Unit Price
Lead Time
Stock Level
Name Number Contact NUmber (US$) (Days)Curren
t MinMax
1Theta axis pulley CR2-033 1 2
2Theta motor A-CR2-194 1 2
3Linear bearing CR2-053 1 2
4Keypad CR2-044 1 2
5Galil mation control card DMC-1040 1 2
6Amplifier icon card A-CB2-110 1 2
7Y axis inter connect card CR2-041 1 2
8X Y axis motor A-CR2-193 1 2
Shop Floor TPM board (Example)
Team D Suggested Layout of Inform ation Board
Suggested Layout of Information Board• Board measures 36X48 mounted -- 40 to 48 inches f rom the floor• Att ach Consumables list to TPM cabinet door• Lockout instructions & map to be loca ted on main electrical cab inet (not on TPM Board)
Lube CriticalCleaning
Route Map
Problem andComponent
Codes
MSS EquipmentProblem Log Sheet
(S.R. Record)
OEE WeeklySummary Sheet
(if Available)
P.M. Schedule
List of personsresponsible for
updating each item onthis board
TPM Information Board
Machine OperatorMachine Name
Operators’ Name(s)
Instructions forLube & Critical
Cleaning
Any Single PointLesson placebehind theseinstructions TPM Management
Walk-throughChecklist
Small GroupActivity
ImprovementItems (form)
Start-up/ShutdownProcess Map on Back
Team D Note:Board construction woodwith cork facing or magnetic
Operator Sign-offSheet (daily)
Quality & Kaizen Overview Quality Improvement Action
Plan Engineering TPM Kaizen
-Improvement Projects to address risk of breakdown
Maximizing Equipment Utilization
After Maintenance Workshop
TPM the Effective Maintenance
05/01/202344
(Kaizen) Focused Improvement
Gradual, unending improvement, doing “little things” better every day, setting and achieving ever higher standards
Engineering TPM (Kaizen) TPM the Effective Maintenance
-Improvement Projects to address risk of breakdown
The Key to One Piece Flow, Just In Time and Lean Manufacturing
IS
Raise inspection and restoration skill levels
Review and improve Cleaning is Inspecting and Lubrication Standards
Enhance visual controls
Ensure operators and maintenance are creating Single Point Lessons
Strengthen Routine MaintenanceTPM the Effective Maintenance
Raise the level of inspection for Operators through Small Group Activities (SGA) and start focusing on attacking the Six Big Losses of Production as a baseline.
Higher level of inspectionTPM the Effective Maintenance
Maintenance to Train Operators on Basic:*Pneumatics*Hydraulics*Electrical Systems*Drive systems*Machine Specific Training
05/01/202348
Training and Education
Pneumatic systemsHydraulic SystemsElectrical Systems
Drive SystemsMachine Specific Training
Skill Specific Training
Maintenance Training For Maintenance group should then focus on Advanced:
*Why are we concerned about equipment lubrication?
*Many moving parts are not lubricated
*Many components are over lubricated
*Lubricants already in components are contaminated
Failures
Components
Resources
Quality
28
50
Lubrication (Yellow)
Air/Vacuum (Blue)
Hydraulic (White)
Water (Green)
Electrical (Red)
Lockout/Tag/Tryout (Orange and Black)
Inspection Checkpoints (White and Black) 3
INSPECTION POINT
AIR PRESSURE80-100 psi
#1Main Air Supply
LOCKOUT
Work place Organization Standards ( Visual Management of Equipment) - Color Coding
05/01/202351
Visual Management Examples
05/01/202352
*Single Point LessonsSingle Point Lessons let you quickly (ten minutes or less) communicate key points on any subject either verbally or visually. You can augment your lesson with visual support if appropriate. Suggested topics for lessons include, though not limited to:
· A specific maintenance procedure· An inspection task for Quality Control· A detail of a safety check· An office procedure, such as record keeping for AM
A well prepared Single Point Lesson stands alone, and can be delivered by anyone who feels comfortable doing so, whether or not they are a subject matter expert.
Elements of PdM (mechanical and electrical) Equipment condition monitoring Predicting potential equipment breakdowns or to avoid expensive repairs
3P Maintenance TPM (Plan, Preventive & Predictive Maintenance)
TPM the Effective Maintenance
Predictive Maintenance Techniques, Applications, and Instrumentation covers;
Starting with a PdM base line (History of Failure) Retighten PM Schedule to include PdM Combining PdM with PM for greatest overall effect and least cost Organizational requirements
TPM the Effective Maintenance Predictive Maintenance (PdM)
Implementation Getting Organized for PdM &Planning for PdM, the preparatory steps;
Predictive Maintenance (PdM) management Implementation program Typical membership of
a team*five to seven operators*a maintenance person*a technical expert
Tools*Pareto*Cause & effect*Root cause*Methods Analysis
TPM the Effective Maintenance
Vibration analysis/monitoring Shock pulse method Spectrographic oil analysis Ferrographic particle analysis Thermography/temperature measurement Non-destructive testing (NDT) Ultrasonic testing and more
Specific PdM Techniques and Applications
TPM the Effective Maintenance
A manager that does not spend 20% of their time involved in TPM is only
offering lip service
Tokutaro SuzukiVice Chairman, Japanese Institute of Plant Maintenance
TPM the Effective Maintenance
The condition of the shop floor
is a reflection of the attitude of
the people!
TPM the Effective Maintenance
I run it,you fix it
I fix it,you run it
Total Productive Maintenance is Not,
TPM the Effective Maintenance
Autonomous Maintenance is Not
A Quick Fix
TPM the Effective Maintenance
For Choosing ITS Management Sdn BhdAs Your Training Provider
If you have questions or require further assistance later, please email to
Email Subject: “Attn: Timothy Wooi”
Other inquiries, please email to