Process Method Inputs Materials Manpower Machinery ...

Introduction to Total Preventative Maintenance

Process

Method

Inputs Materials

Manpower Machinery

Outputs Q , C , D

Cust Satisfaction

Q , P , D

Improvement

Reactive

The Process Model


Process

Method

Inputs Materials

Manpower Machinery

Outputs Q , C , D

Cust Satisfaction

Q , P , D

Improvement

Concept of Zero - to achieve zero losses concentrate upon losses

In inputs

Reactive

Cannot equal zero

Proactive

Concentrate on Inputs


Total Productive Maintenance


JIPM Approach / Principles

1. Establish a corporate culture to maximise production system efficiency 2. Gemba Genbutsu3. Involve all functions 4. Involve all members 5. Achieve zero losses


24 Months

Timeline

18 Months

6 Months


Types Of Losses

Chronic – Losses related to problems that we learn to live with

Sporadic – Catastrophic Losses that are not an inherent part of the process.

Memorable events

What is a loss ? – an event or series of events leading to a reduction in the Effectiveness or efficiency of a process

Types Of Losses


1 Breakdowns2 Setup and Adjustment3 Cutting Blade replacement4 Start up 5 Minor Stoppages 6 Speed Reduction7 Defects and Rework

16 Process Losses

9 Management Loss 10 Motion Loss 11 Line Organisation12 Distribution Loss13 Measuring & Adjustment

14 Yield 15 Energy 16 Die , Jig & Tool Loss 8 Shutdown

Machinery

Materials

Manpower

Availability

Performance

Quality


1 Breakdowns2 Setup and Adjustment3 Cutting Blade replacement4 Start up

Machinery Losses

8 Shutdown

Availability Losses

Equipment failureChangeover of equipment to new size or product Replacing new wear components i.e. cutting blade Time to get equipment running after start-up

5 Minor Stoppages 6 Speed Reduction

7 Defects and Rework

Refilling hoppers, minor stops plus idlingRunning at reduced speeds

Rejected or reworked products

Planned closure

Performance Losses Quality Losses

% of time process not running during planned

production time

% of output lost against ideal capacity from actual

production time

% of Output lost due to poor quality


9 Management Loss 10 Motion Loss 11 Line Organisation12 Distribution Loss13 Measuring & Adjustment

Manpower Losses

Availability Losses

Excessive time spent organising processExcessive movement of personnel Excessive time organising area for normal running Excessive time moving materials & products Excessive time measuring outputs & adjusting

Performance Losses Quality Losses

% of time process not running during planned

production time

% of output lost against ideal capacity from actual

production time

% of Output lost due to poor quality


Why do we get Breakdowns ?Operating Conditions Not being followed

Why do we get break downs ?

Deterioration not beingChecked

Inherent Design weakness

Inherent Design weakness

Poor basic conditions


Focussed Improvement - FIAutonomous Maintenance – AMPreventative Maintenance – PMTraining & Education – T&EEarly Management – EMQuality Maintenance – QMOffice TPM – OTSafety , Health & Environment - SHE

8 Pillars of TPM

Phase 1 – Establish base conditions & understand your process Phase 2 – Standardise your process and sustain improvementsPhase 3 – Achieve zero Losses

Phase 1

Phase 3

Phase 2


Make Source Deliver Supplier Customer

Innovation

Supply Chain

Plan

Product Development

Phase 1

Phase 2

Phase 1 – FI + AM + PM + T&D

Phase 2 – FI + AM + PM + T&D + QM + EM


Corporate Governance of TPM

Focu

ssed

Impr

ovem

ent

Auto

nom

ous M

aint

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ce

Plan

ned

Mai

nten

ance

Trai

ning

& E

duca

tion

Qua

lity

Mai

nten

ance

Early

Man

agem

ent

Offi

ce T

PM

Safe

ty H

ealth

& E

nviro

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t

Pillar Leads

Plant Leader

Steering Committee

Performance KPI’s

Resource , Targets Support

Daily Management

Engaged Organisation


Autonomous Maintenance


Fact : All Processes Deteriorate

Forced deterioration accelerates process failureExample : Contamination , Damage & Vibration

Objective of Autonomous Maintenance ( AM )

Eliminate Forced deterioration of process & equipment by engagement whole workforce in maintaining optimal conditions


0: Preperation1. Initial Clean up – Discover Faults 2. Eliminate Causes of Contamination 3. Prepare tentative cleaning & Lubrication standards 4. Improve inspection and technical skills 5. Autonomous Checking of machines 6. Standardise Procedures & work place rules 7. All Out Autonomous Maintenance

7 Steps of AM

All Processes Deteriorate Forced deterioration accelerates

process failure1. Contamination 2. Damage 3. Vibration

Objective of AMEliminate forced deterioration of

process & equipment by engagement whole workforce in maintaining

optimal conditions


7 Stages of Autonomous Maintenance

Amount of Basic Maintenance Tasks by Operators

Amount of Basic Maintenance Tasks by Mechanics

1

2

4

3

5

6

7

Mechanics

Operators


0.0 Step Training0.1 JSA Review 0.2 Validate / Create LOTO Map and post on machine0.3 Principle of Motion Training ( POM ) on machines

Incl Normal vs Abnormal Machine FunctionIncl Forced vs Natural Deterioration

0.4 Current all OPL for machine 0.5 Write a OPL listing all safety hazards on machines 0.6 Team & Managers Audit

vs master plan

Steps 0 : Stages for preparation


Stages

1. Define Approach & Baselines 2. Sort and Set 3. Deep Cleaning4. List and correct F-Tags 5. Develop Tentative Cleaning Standards6. Maintain List of OPL’s

1. Incl OPL with all potential safety hazards of machine

Steps 1 : Initial Clean Up


Clean Each Component of equipment to discover potential problems FUGUAI

1. Minor Flaws 2. Unfilled basic conditions 3. Inaccessible Places 4. Contamination Sources5. Quality Defect Sources 6. Unnecessary and Non Urgent Items7. Unsafe Places

Steps 1 : Initial Clean Up


Step 2 : Eliminate Causes of Contamination

NB: at least 85% of F Tags must be eliminated to move to step 3

Cleaning is inspection


Step 3 : Prepare tentative cleaning & Lubrication standards

NB: Operators Learn the importance off lubrication and how to effectively lubricate their machines

Audit Score of at least 80% or better to advance to step 4

3.0 Step Training 3.1 Continue Weekly Cleaning & Inspection

3.2 Study Lubrication

3.3 Identify & Mark Lubrication Points

3.4 Prepare Tentative Lubrication Standards

3.5 Train Operators to lubricate their

own machines

3.6 OptomiseSequence for C-I-L

Standard

3.7 Update Visual Controls to make C-I-L more efficient

3.8 See if reduction in C-I-L time

3.9 Team & Manager Audit Audit

Time


Step 4 : Improve inspection and technical skills

Introduction to Total Preventative Maintenance AM – Tools


Corporate Governance of TPM

Focu

ssed

Impr

ovem

ent

Auto

nom

ous M

aint

enan

ce

Plan

ned

Mai

nten

ance

Trai

ning

& E

duca

tion

Qua

lity

Mai

nten

ance

Early

Man

agem

ent

Offi

ce T

PM

Safe

ty H

ealth

& E

nviro

nmen

t

Pillar Leads

Plant Leader

Steering Committee

Performance KPI’s

Resource , Targets Support

Daily Management

Engaged Organisation

Introduction to Total Preventative Maintenance EM – Tools

1 Criticality Matrix - rank all equipment regards its criticality to the organisation2 move from breakdown to preventative and condition based maintenance3 Track all breakdown perform a 5 why analysis & track occurrence & NAEEM M-P to ensure more robust parts are substituted


EM – (AM – EM) 7 Stage Integration


The 7 Stages of Integration of EM and AM


EM – Maintenance Pyramid


Who Should be involved ?

Production Maintenance Quality HR & Admin Finance TPM

FI O X X

AM O X X

PM O X

T&E X X O X

EM O X

QM X O X

OT X x O X

SHE x O X

O – Lead , x - Support


Tools used - not complete

Cost and loss tree Plant and loss tree Loss Tree 12 step Kaizen Why –why analysis 5W – 1H analysis

Process Method Inputs Materials Manpower Machinery ...

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