Transcript Total Productive Management - Multi Environment Solutions

Total Productive Maintenance
Multi Environment Solutions
Aims of TPM
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To maximize the production system
To organize a practical shop-floor system
Zero accidents
Zero defects
Zero breakdown
To involve all the functions of an
organization
To involve every employee
To achieve Zero loss
The Pillars of TPM
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Focused improvement
Autonomous maintenance
Plant- Maintenance
Office Maintenance
Product Design and Equipment Initial
Control
Quality Maintenance
Worker’s Education & Training
Safety, Hygiene & Environment Control.
TPM Goals
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Achieve zero breakdowns & zero losses thru
- Focused Improvement,
- Effective Equipment Management Techniques
- Autonomous Maintenance
Systems.
Cont.
TPM Goals
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Prevent losses before they occur thru
- Integrated functions of production
- Maintenance
- Technical
- Commercial
- Administration
- Finance
- Marketing.
Cont.
TPM Goals
Achieving zero defects, to
- become a consistent supplier of
quality products and services
- conform customer specifications.
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Cont.
TPM Goals
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Give effective training to
develop highly skilled, motivated
and self-reliant workforce.
Prolong life span of equipment by
maintainability improvement.
Cont.
TPM Goals
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Involve all the members of the team to
develop an atmosphere that is
- congenial
- friendly
- energetic
which is resulting in pride of job
performed with a feeling of
ownership of the asset.
Cont.
TPM Goals
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TPM
ensures
environment that is
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a
working
Clean
Accident free
Pollution free
Cont.
TPM Organization
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TPM promotion committees:
Company TPM Promotion Committee
Plant Promotion Committee
Subcommittee of Kaizen
Sub-committee of Autonomous Maintenance
Sub-committee of planned maintenance
Sub-committee of initial flow control
Sub-committee of Quality Maintenance
Sub Committee of office improvement
Education and training committee
Safety and Hygiene Committee
Role of TPM Promotion
Committee
- Basic policy and Target Setting
- Audit of the promotion progress and
the education and cultivation of
Implementation plan.
- Approval of implementation plan
Workout remedial measures against
problems
encountered
during
promotion of the activities.
- Organize the project teams.
Role of the Plant
Promotion Committee
- Workout the plan to promote JishuHozen
and
Kobetsu-Kaizen
and check the progress of
promotion activities.
- Review problems and give
instructions to small groups
- Organize Kobetsu-Kaizen project
teams.
Role of the
Subcommittee of Kaizen
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Instruct on how to practice
“Kobetsu-Kaizen”
- Instruct on how to horizontally
replicate TPM.
- Analysis of improvement activities
– Quantitative and Qualitative
- Standardization and information
exchange.
Role of the Company
TPM Promotion
Committee
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Study how to proceed with the
autonomous maintenance step by step
Development.
- To conduct Audit after completion of
each
step
for
assessing
progress & guidance for subsequent
work.
Role of the Subcommittee of planned
maintenance
- Study how to advance the phase
development.
Instruct how to advance KobetsuKaizen.
Instruct how to horizontally replicate
TPM
Standardization of various items and
information exchange
Role of the Subcommittee of initial flow
control
- Study cases
- Review existing system
- Standardize various items
- To optimize life cycle cost, as well
to improve equipment reliability by
Maintenance prevention design.
Role of the Subcommittee of Quality
Maintenance
- Study of Himanshitu techniques
Instruct
how
to
advance
Himanshitu-Hozen
- Instruct how to horizontally replicate
TPM
- Standardization of various items
and information exchange
Role of the Sub
Committee of office
improvement
- Study how to advance the step
development
- Instruct how to advance KobetsuKaizen
- Instruct how to horizontally replicate
TPM
- Standardization of various items
and information exchange
Role of the Education
and training committee
- Work out the training plan
- Check the promotion progress and
review problem
Role of the Safety and
Hygiene Committee
- Educating Safety and Hygiene
systems
- Control of safety and Hygienic
condition
TPM Implementation
Steps
 Building Management will
 Establishing common TPM Language
 Announcement by top Management
 Introductory Education and campaign
 Work Environment the 5S
 Establishing TPM promotion organization and setting
up model equipment.
 Setting basic policy and Target for TPM
 Creation of Master Action Plan
TPM kick off
Cont..
TPM Implementation
Steps
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Establishing systems for improving
production efficiency
a. Problem Solving Tools
Training on Tools
Continuous application of tools
b. Waste Elimination
c. Kaizen
d. Autonomous Maintenance
e. Planned Maintenance
f. Education and Training
Cont..
TPM Implementation
Steps
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MP Design and equipment initial
control
Quality maintenance
Office TPM
Safety, hygiene and pollution control
Measuring and Monitoring – Visual
Management
Preparation for PM excellence award by
JIPM
JIPM Final Assessment for PM
excellence award.
Major Losses
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Shutdown Losses
Production Losses
Equipment failure Losses
Process failure Losses
Normal Production Losses
Abnormal Production Losses
Quality Defect Losses
Reprocessing Losses
Management Losses
Motion Losses
Line Organization Losses
Cont.
Major Losses
- Losses resulting from lack
of automated system
- Measurement Losses
- Yield Losses
- Energy Losses
- Die, Jigs and tools Losses
The common functions
of all the Pillars
- Objectives of TPM
- Goals of TPM
- Implementation Plan for TPM
- Loss Structure
- TPM Promotion Committees
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Minutes
of
meeting
of
Promotion Committees/Action Plan
- Processes/Sub-Processes
TPM Audits
TPM
Focused Improvement
includes all activities that maximize
the
overall
effectiveness
of
equipment, processes and plant
through elimination of losses and
improvement of performance. The
overall Plant effective (OPE) is
calculated as follows:
OPE= Availability of Plant x
Performance Rate x Quality Rate
Focused improvement
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Implementation Steps
Registration of Improvement Topic
Improvement Targets
Implementation Plan for the Topic
Results of Improvement
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Focused Improvement Audit
Autonomous
maintenance
This emphasizes the need for
individual workers to carry out
routine inspection, oiling, repairs,
detection of abnormalities of their
own equipments for the purpose of
“Protecting their own equipment”.
Autonomous
maintenance
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Implementation Steps
Autonomous Activities
Autonomous Maintenance Tags
Autonomous Maintenance Standards
One Point Lessons
Equipment Evaluation Criteria
Equipments
for
Autonomous
Maintenance
Abnormalities and Counter measures
Visual Controls
Cont..
Autonomous
maintenance
Analysis of MTBF (From
Plant Maintenance Module)
- Autonomous
Audit
Maintenance
Plant Maintenance
- Implementation Steps
- Equipment Data Base, Specifications and
Configuration
- Maintenance Activities, Spares Required,
Procedure, Safety Precautions
- Break Down Maintenance
- Planned (Time Based Maintenance)
- Opportunity Maintenance
- Lubrication Schedule
- Inspection Schedule
- Calibration of Instruments
Cont..
Plant Maintenance
- Shut Down Maintenance
- Reading of various equipments (Condition
Based Maintenance)
Resources
required/consumed
for
Maintenance
- History of Maintenance/Log Books
- Budget Vs. Actual cost of Maintenance
- Planned Maintenance Audit
Office Maintenance
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Office Functions
File/Document Analyzing Forms
Office Function work Method
Daily Work Survey
Work Allocation
Daily/Monthly work summary
Monthly load Chart
Product Design and
Equipment Initial
Control
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Aims
Product Information Points
Life Cycle Cost
Product Design Information Sheet
Quality Maintenance
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Quality Maintenance Aims
Quality Defect Factors
Steps of Quality Maintenance
Present Status of Process
Process which cause defects
Analysis of 4M(Man, Machine, Material
and Method)
Countermeasures
Conditions for 4M that do not produce
defects
Checking Methods
Standards
Quality Maintenance
- Quality Improvement Results
- Defect Rate (From Lab Test Module)
- Customer Complaint Rate (From
Customer Feed Back Module)
- Reprocessing Rate (From Production
Module)
- Quality Variation (From Lab Test Module)
Worker’s Education &
Training
- Training needs
- Worker’s Skills
- Training Programs
- Training Schedules
- Training Infrastructure
- Faculty
- Training Cost
- Feedback
- Training Budget/Utilization
Safety, Hygiene &
Environment Control
- Accidents
- Safety Training, first aid, emergency
handling Procedure
- Safety Manuals
- Health Check up of Employee
- Pollution Control Checks and Results
- Drinking Water Tests
- Safety Audit
- Hygiene Audit
Customer Feed Back
- Feed Back Type
- Receipt of Customer Feed
Back/Complaint
- Customer Complaint Response,
solution, action
- Effect of Complaints