Transcript Partners for Creative Solutions

Partners for Creative Solutions, Inc.
36 Deerfield Rd, Shrewsbury, MA 01545
508 845-1546 [email protected]
Total Productive Maintenance
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Partners for Creative Solutions, Inc.
TPM Training Agenda
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TPM – History, benefits and typical results
Definition and “5 Pillars” of TPM
The “6 Big Losses”
Autonomous Maintenance
Maintenance Prevention
Setting Standards & Sustaining the Benefits
TPM and Safety
The Advisory Team
Equipment Improvement Teams (EIT’s)
TPM vs. 5S
Summary of TPM topics
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Partners for Creative Solutions, Inc.
Origins of TPM
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Breakdown maintenance (RTF) - historical
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Preventive Maintenance concept – introduced in1951
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Productive Maintenance introduced later
 Included
 Preventive maintenance
 Improvement-related maintenance
 Maintenance prevention
 Still primarily maintenance department
 Never achieved zero breakdowns or defects
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Partners for Creative Solutions, Inc.
Origins of TPM
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Total Productive Maintenance
 Brought operators into the picture
 Small group activities
 Teamwork between operators and maintenance
 Involvement & support throughout the company
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Partners for Creative Solutions, Inc.
No Tolerance for Breakdowns
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Equipment breakdowns impact
 Customer
service
 Production costs
 Maintenance costs
 Effectiveness of “manufacturing cells” or “flow
lines”
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Breakdowns result in “chaos”
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Partners for Creative Solutions, Inc.
The Last 50 Years
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In the 1950’s, about 70% of durable goods sold in
the world were made in the U.S. …today << 10%
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In the 1950’s, there were over 25 U.S. television
manufacturers …by the early 1990’s, only 1
(Zenith) …today??
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In the 1950’s, the largest growing job was in
manufacturing…not the case today!!
Most manufacturing industries are fighting a war
to survive!
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Partners for Creative Solutions, Inc.
Benefits of TPM to the Company
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Improved plant productivity and capacity
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Lower operating costs
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Improved equipment lifespan
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Better ability to satisfy customers
Bottom Line: TPM increases
long-term viability
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Partners for Creative Solutions, Inc.
Benefits of TPM for Operators &
Maintenance Personnel
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Increased skills through additional training
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Better job satisfaction
– More involvement in solving annoying
equipment problems
 Maintenance – More challenging work
 Operators
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Better job security
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Partners for Creative Solutions, Inc.
Typical TPM Results
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Overall equipment effectiveness up 25-65%
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Quality defects down 25-50%
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Maintenance expenditures down 10-50%
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Percent planned vs. unplanned maintenance
increased 10-60%
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Partners for Creative Solutions, Inc.
Definition
TPM is a company-wide system developed to
maintain, monitor, and improve all capital assets
of a company. For production it is a system that
maximizes equipment effectiveness and
maintains product flow.
 TPM
is not just about “maintenance”. It is about
getting the most overall benefit from your equipment
over the life of the equipment.
 TPM will not be an overnight success. Implementing it
throughout a plant correctly will take several years.
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Partners for Creative Solutions, Inc.
Shift in Attitudes
Operator
Maintenance
Operator Maintenance
I use
I maintain &
I fix
We maintain
Conventional
TPM
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Partners for Creative Solutions, Inc.
5 Pillars of TPM
1.
Improvement activities designed to increase
equipment effectiveness (OEE)
2.
Autonomous maintenance program performed
by equipment operators
3.
A planned maintenance system
4.
Training to improve operation & maintenance
skills
5.
Effective new equipment design and startup
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Partners for Creative Solutions, Inc.
TPM Emphasizes Prevention
Three Principles of Prevention
1.
Maintain normal conditions
2.
Early discovery of abnormalities
a)
b)
3.
Operator
Maintenance
Prompt response
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Partners for Creative Solutions, Inc.
The Six Big Equipment Losses
1.
Breakdowns
2.
Setups and adjustment
3.
Idling and minor stoppages
4.
Speed
5.
Quality defects and rework
6.
Start-up (loss of yield)
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Overall equipment effectiveness = Availability x Performance rate x Quality rate
(OEE)
Breakdown
Setup and adjustment
Others
Idling & minor stoppages
Reduced speed
Quality defects & rework
Start-up yield
Operation time (Scheduled time available – Downtime)
Availability = ______________________________________________ x 100
Scheduled time available
processed amount x ideal cycle time
Performance rate = _____________________________
Operation time
Quality rate =
Amount good / amount produced
Partners for Creative Solutions, Inc.
Improving OEE
1.
Measure the extent of the 6 big losses
2.
Analyze the causes (but focus your efforts )
3.
Develop solutions & create an improvement plan
4.
Set targets and estimate the benefits to OEE
5.
Carry out the plan
6.
Establish measurements to monitor results
7.
Repeat as necessary
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Eliminating Breakdowns
Workplace Conditions Contribute to Losses
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Filthy equipment
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Oil and lubricant leaks
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Moving parts encrusted with raw materials or debris
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Disorderly wiring, hoses, etc.
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Equipment mechanisms hidden or difficult to access
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Workplace disorder
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A belief that conditions cannot improve
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Partners for Creative Solutions, Inc.
Eliminating Breakdowns
Why machines fail
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Disregard for basic needs (housekeeping, lube..)
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Incorrect operating conditions
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Lack of skill or knowledge of operator
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Machine deterioration
 Routine
 Accelerated
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Design deficiency
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Partners for Creative Solutions, Inc.
Eliminating Breakdowns
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Two kinds of breakdowns
 Function
loss (function completely lost) - Sporadic
 Function reduction (works, but with loss of speed or
quality) - Chronic
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Two kinds of breakdown maintenance
 Planned
(pre-emptive)
 Unplanned (firefighting)
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Partners for Creative Solutions, Inc.
Autonomous Maintenance
The principal way production workers participate in
TPM
Purpose
1.
2.
3.
Brings production & maintenance people together to
slow routine deterioration and halt accelerated
deterioration
Helps operators learn more about their equipment
(the cause and effect)
Prepares operators to be active partners with
maintenance and engineering in improving equipment
performance and reliability
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Partners for Creative Solutions, Inc.
Steps to Implementing Autonomous
Maintenance
Step 1:
Initial cleaning and inspection
Step 2:
Eliminate sources of contamination and
inaccessible areas
Step 3:
Develop and test cleaning, inspection,
and lubrication standards
Step 4:
General inspection training and
inspection procedures
Step 5:
Conduct autonomous general
inspections
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Partners for Creative Solutions, Inc.
Steps to Implementing Autonomous
Maintenance
Step 6:
Organize and manage the workplace
Step 7:
Ongoing autonomous maintenance and
continued improvement
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Partners for Creative Solutions, Inc.
An advanced Improvement method
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Maintenance Prevention
Design-stage activities aimed at making new equipment
reliable, easy to care for, and user friendly
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Partners for Creative Solutions, Inc.
Sustaining TPM
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Audits
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Visual activity boards
 Team
 Team
charter
activities, goal, schedule, and progress
 Cleaning, inspection, and lubrication standards
 Workplace organization standards
 Trend charts for each of the big 6 losses
 Inspection reports
 Audit results
 Before and after photos
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Partners for Creative Solutions, Inc.
TPM and Safety
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Safety is the cornerstone of
production activities
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Accidents usually occur when unsafe
behavior is combined with
unsafe conditions
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For every major accident there are
29 minor accidents and 300 near misses
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Safety should always be the #1 priority
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Partners for Creative Solutions, Inc.
Setting Up a TPM Structure
EIT
EIT
EIT
TPM
Advisory
Team
EIT
Mgmt
EIT
EIT
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Partners for Creative Solutions, Inc.
Advisory Team - Responsibilities
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Guide & champion TPM implementation
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Assess current equipment OEE and develop a
process for measuring the “6 big” losses
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Develop a TPM master plan
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Set plant-wide standards for TPM implementation
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Monitor and evaluate progress
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Serve on EIT’s
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Partners for Creative Solutions, Inc.
Equipment Improvement Teams Responsibilities
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Return equipment to near new condition
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Investigate and reduce the “big 6” equipment
losses
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Transfer routine maintenance skills to operators
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Set standards for routine maintenance and
inspections by operators
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Organize the work area for more
effective/efficient maintenance
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Partners for Creative Solutions, Inc.
Setting Goals for Your TPM Program
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Short term – 12 months
 Establish
an autonomous maintenance program for “x”
machines
 Increase OEE by “y”% within for individual work
centers
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Long term – Reach a plant OEE of 85% within 3
years (world class is considered about 85%)
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Partners for Creative Solutions, Inc.
Comparing TPM to 5S
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5S emphasizes
 Productivity of workers
 Organizing and visual indicators
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TPM emphasizes
 Effectiveness of equipment
 Partnership between maintenance &
 Reducing lifetime equipment costs
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production
Both emphasize
 Initial cleaning
 Safety
and repair
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Partners for Creative Solutions, Inc.
Shift in Equipment Maintenance
Activities
FROM
THIS
to
THIS
Breakdown
Predictive
Planned repair
Planned repair
PM
PM
Breakdown
Autonomous
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Partners for Creative Solutions, Inc.
Review of TPM’s benefits
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For the company
 Higher
Overall Equipment Effectiveness
 Less “firefighting” to repair machines
 Lower operating costs
 Better able to meet commitments to customers
 Improved ability to compete in the world marketplace
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Partners for Creative Solutions, Inc.
Review of TPM’s benefits
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For employees
 Less
pressure on maintenance for urgent repairs
 Less pressure on production to recover from
breakdown losses
 Better cooperation between maintenance, production,
and other departments
 Reduced chance of accidents
 Higher job satisfaction
 Improved job security
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