Transcript Document
Total Productive Maintenance and FTM From Werardt A presentation by Werardt Systemss P Ltd 1 Why TPM? Increases Productivity • Labor productivity, and • Break down reduction Improves Quality by • Reducing the Defects in processes • Reducing Defects in products • Reducing Customer complaints 2 Why TPM? Reduces Cost • Reduction in man power • Maintenance cost reduction • Energy Conservation Delivery • Stock reduction • Inventory turnover increase Safety Environment • Improvement Ideas increase • Small Group meetings increase 3 Why TPM? Financial • Return on Investment (ROI) after 2 to 3 years • Break even on initial TPM project – Less than one year • Reduction in absenteeism, as work place is enriched 4 TPM Goals • Zero unplanned Downtime • Zero Defects • Zero failure • Zero variability • Reduced Idle time on machines • Zero Accidents • Maximized P.M. Compliance • Thus Maximizing OEE FTM puts you on the road to achieve these Goals in a Simple, Better and Faster way ! 5 The Pillars of TPM 1 Kobetsu Kaizen - Individual Improvements 2 Jishu-Hozen - Autonomous Maintenance 3 Planned Maintenance 4 Quality Maintenance 5 Education and Training 6 Safety and Environment 7 Office TPM 8 Development Management TPM is a cultural change and FTM supplements it in Information management 6 Some “Facts” about TPM & Maintenance • Maintenance can generally account for a major portion of today’s manufacturing costs • Hence when it comes to TPM implementation the Maintenance department generally takes the lead • Generally upto 25% of maintenance cost is wasted or not known • Emergency repair jobs are at least three times more expensive than the same repair done a pre-planned basis. Hence TPM & Maintenance go hand-in-hand 7 How to achieve Zero Breakdowns? • RCFA - Root Cause Failure Analysis • Making P.M. effective and dynamic • Condition & Time Based Maintenance • Doing Why-Why Analysis and maintaining 6W2H • Improving the Reliability of work • Reducing Idle time on repairs • Condition Monitoring and Inspection • Autonomous Maintenance activities FTM is very strong in this area ! 8 The FTM Steps to Success • Awareness : Understanding your activities, Identifying Critical, Essential and Desirable requirements • Business Process Optimization : What processes do you follow to achieve your objectives? Who is doing what? Are they trained for the Job? Are required skills available? • Quantification : How many and which type of Jobs do you do? To focus on the type of work being done, how much is reactive and how much is proactive? • Benchmarking : FTM helps in devising and defining your Key measuring parameters or KPI’s that help in Improvements • Performance Review : And most importantly devising a post implementation review mechanism to monitor progress 9 Maintenance Prevention Design • Facilitating autonomous maintenance or Jishu Hozen, through Activity based PM, and feedback on machine behavior • Applying Kaizen activities to monitor Improvements • Increasing the ease of operation, make it easy from information and work point of view • Improving skills through need based training programs and easy availability of history • Improving maintainability through condition monitoring and reliable operations • Improving safety through awareness Applying FTM feedback ! 10 Key Result Areas 1. Improving human resources • Operators’ ability to perform Jishu-Hozen • Maintenance employees’ ability to perform quality & reliable maintenance • Production engineers’ ability to execute maintenance free equipment plan 2. Improving Plant & Machinery • Maximizing Uptime • Increased Plant value • Achieving TPR - Total Plant Reliability 11 Key Result Areas 3. Improving the corporate culture • From authoritarian to participative management • Involving everyone in CIP 4. Reducing losses • Down time losses • Speed losses • Defect losses FTM directly and indirectly helps you in achieving the above 12 Contact Information Werardt Systemss Pvt Ltd Pune, India Phone : 91-20-25285256, 25285257 Website : http://www.werardt.com email: [email protected] 13