ASIA BREWERY - TPM CONSUL

12 Steps to implement TPM

Step 1: Formally announce decision to
introduce TPM

Step 2: TPM introductory education and

publicity campaign

Step 3: Create a TPM promotion organization

Step 4: Establish basic TPM policy and goals

Step 5: Preparation of Masterplan for

implementing TPM

Step 6: Kick-off TPM initiatives

6-1 Individual Kaizen
 6-2 Autonomous Maintenance

Step 7: Build a corporate constitution to

maximize productive effectiveness
7-1 Individual Kaizen
7-2 Autonomous Maintenance

7-3 Effective Maintenance

7-4 Training
Step 8: Early stage management

Step 9: Quality Maintenance programme

Step 10: TPM in the office

Step 11: Safety, Hygiene and Environment

programme

Step 12: Full TPM implementation and raise

levels
ASIA BREWERY - TPM CONSULTATION ACTIVITY PLAN
Activities Who
President to declare to the Board to implement TPM. Declaration to be President
Officially Communicated across the Company
Formal Cascade of the Declaration to each Department HR Department
Selection of Manager's Model Line & Model Line Team Organization Plant Head

Training on TPM appreciation & Overview for Executives & Department TPM Consultant
Managers
Training on TPM Specific Methods to Progress the 8 Pillars for: TPM Consultant
a. Department Supervisors
b. Line Leaders
c. Pillar Leaders

Cascade/Training of the TPM Implementation Overview and How to TPM Promotions Head
Progress TPM Pillars for:
a. Manufacturing Technician
b. Engineering Technician.

Announcement of TPM Steering Committee and appointment of TPM Manufacturing VP

Corporate Coordinator & Site TPM Facilitator
Drafting and Approval of Corporate TPM Policy and Goals Manufacturing VP

Inventory and Classification of Machine Category TPM Promotions Head

Drafting and Approval of Department TPM Policy and Goals Department Heads

Communicate and align with JIPM on the following directions: TPM Promotions Head
1. ABI Cabuyao to apply for accreditation as one Consolidated Site
consisting of four (4) Plant.
2. San Fernando to apply as separate plant but under the same Steering
Committee as ABI Cabuyao.

Draft TPM Corporate Masterplan TPM Promotions Head

Draft TPM Masterplan for Cabuyao Plant and San Fernando Plant Plant Head

Draft TPM Pillar Masterplan per Plant Pillar Heads

Deep Dive Training Loss Measurement for Model Line Members TPM Consultant
Develop and Implement a System for Loss Measurement Data Capture FI Pillar Leaders
aligned with Finance Department
Collection of OEE Performance and Losses and encoding into system AM Pillar Leader and
AM Pillar Leader
Training - How to progress Kaizen for Model Line Members TPM Consultant

Deep Dive Training on AM Steps 1-4 for Model Line Members TPM Consultant
1. Orientation of OEE Performance and Loss Definition
2. Tagging ON/Tagging OFF
3. Mapping of SOD and HAA
4. How to set Tentative CILT Standards
5. How to use simple Tools
6. The three Jewels of AM
7. How to set up AM Activity Board

Set-up the KPI and KAI for Model Line Model Line Members

Conduct STEP 1 Activity for Model Line Model Line Members

PASS STEP 1 Audit for Model Line Model Line Members

PASS STEP 2 Audit for Model Line Model Line Members

PASS STEP 3 Audit for Model Line Model Line Members

PASS STEP 4 Audit for Model Line Model Line Members

Note: Model Line Manufacturing Technician at SKILL LEVEL 4 after STEP 4

Launch OEE and Loss Data Capture Loss for across plants align with IE and TPM Consultant
Finance

Masterplan - Review and re-alignment TPM Consultant

Establish Framework for the OEE Loss Tree and Cost Loss Tree Governance TPM Promotions Head
and FI Pillar Leader
Targets - Identifying Cost Savings Projects (Kaizens) and Setting up Targets Pillar Heads
for Cost Savings Delivery

Coaching in the Execution and Development of Kaizens TPM Promotions Head

and FI Pillar Leader

Masterplan - Review and re-alignment TPM Consultant

Targets - Review & Finalize KPIs and KAIs for AM Pillar TPM Consultant

Roll Out Training in AM Steps 1-4 TPM Promotions Head

and AM Pillar Leader
Setting up AM Activity Boards by AM Teams TPM Promotions Head
and AM Pillar Leader
PASS AM Steps 4 Audit on 76% of Production Lines TPM Promotions Head
and AM Pillar Leader
Start Implementation Activities for STEP 5 TPM Consultant

Masterplan - Review and approval TPM Consultant

Targets - Review and Finalize KPIs and KAIs for PM Pillar TPM Consultant

Training on the Principles of PM and how to progress the 7 Steps of TPM Consultant
Planned Maintenance

Training on the Principles of BDM, TBM, CBM and CM TPM Consultant

Training on the Methods of Failure Analysis and the Use of Emergency TPM Consultant
Work Orders

Training on the Principles of Spares Management TPM Consultant

Masterplan - Review and approval TPM Consultant

Targets - Review and Finalize KPIs and KAIs for T&E Pillar TPM Consultant

Setting-up of Technical Training Center TPM Promotions Head

and T&E Pillar Leader
 TPM Promotions Head
and T&E Pillar Leader
Assessment and Training on Operational Skillsfor Manufacturing
Technicians:
1. Machine Safety points
2. Process CCPs and Quality points
3. Start up and shutdown procedures
4. Trouble Shooting procedures
TPM Promotions Head
and T&E Pillar Leader
External Training on the Generic Skills for Manufacturing Technicians
1. Mechatronics (Hydraulics & Pneumatics)
2. Fasteners
3. Drives
4. Lubrications
5. Metrology
6. Sketching
TPM Promotions Head
Training on Technical Skills for Manufacturing Technicians AM STEP 4 and T&E Pillar Leader
1. Repair and replacement basic Machine Component (Sensor, Belts,
Heaters, Bearings. etc.)
2. Proper Lubrication
Masterplan - Review and approval TPM Consultant

Targets - Review and Finalize KPIs and KAIs for EEM Pillar TPM Consultant

Training Orientation on the Principles and How to Implement EEM Pillar TPM Consultant

Training on EEM Tools and Techniques (FMEA, LCC and MP Design) TPM Consultant

Establish System for MP Information Database TPM Consultant and

EEM Pillar Leader

Identification and Implement on Pilot Project EEM Pillar Leader

Establish System for Standard application on all Project EEM Pillar Leader
Masterplan - Review and approval TPM Consultant

Targets - Review and Finalize KPIs and KAIs for QM Pillar TPM Consultant

Training on the & QM Steps (figure of 8) TPM Consultant

Develop and Establish QM Matrix TPM Consultant

Training on QC Tools TPM Consultant

Training on PPA TPM Consultant

Identify Focus Issues and Progress Activities to ZERO Defects QM Pillar Leader
Updating of Standards to Sustain ZERO Defects Conditions QM Pillar Leader

Masterplan - Review and approval TPM Consultant

Targets - Review and Finalize KPIs and KAIs for Office TPM Pillar TPM Consultant

Establish 5S Steering Committee OTPM Pillar Leader

Training on 5S OTPM Pillar Leader

Identify Model Area for Office TPM OTPM Pillar Leader

Set up System for 5S Audit (5S Patrol, etc.) OTPM Pillar Leader
Training and Orientation on the Development of the Five CORE Activities TPM Consultant
for Office TPM

Identify Projects and Implementation of Improvement Activities OTPM Pillar Leader

Masterplan - Review and approval TPM Consultant

Targets - Review and Finalize KPIs and KAIs for SHE Pillar TPM Consultant

Review and Update Legal Requirement for the Site SHE Pillar Leader
Analysis of incidents with root causes. Collect & record NM, UC&UA SHE Pillar Leader

Corrective and preventive actions and horizontal deployment SHE Pillar Leader
Launch Risk Management and setting basis for Site safe Procedures SHE Pillar Leader
Launch SBO and DCA Program to enable people to care for safety SHE Pillar Leader
Actions taken on Risk Management, SBOs and DCAs SHE Pillar Leader

Preparation of Activity Report and Documentation for JIPM Assessment TPM Promotions Head

Preparations for Site Assessment Audit including Kaizen Presentation TPM Promotions Head
Boards
PLAN
Resource Timing
TPM Promotions Head March, 2019

Department Head March, 2019

TPM Promotions Head, Site March, 2019
AM Pillar Leaders & TPM
Consultant
TPM Promotions Head March, 2019

TPM Promotions Head March to April, 2019

TPM Consultant & Pillar April - May, 2019

Leaders

TPM Promotions Head & March, 2019

Department Heads
TPM Promotions Head & March, 2019
Department Heads
TPM Consultant & Pillar March, 2019
Leaders
TPM Promotions Head & April, 2019
TPM Facilitators
TPM Consultant

TPM Consultant March, 2019

TPM Promotions Head and April, 2019

TPM Consultant
TPM Promotions Head and April, 2019
TPM Consultant

TPM Promotions Head, FI April, 2019

Pillar Leader & Training
Pillar Leader
TPM Promotions Head April, 2019

TPM Promotions Head April, 2019

TPM Promotions Head, FI April, 2019

Pillar Leader & Training
Pillar Leader

TPM Promotions Head, AM April - May, 2019

Pillar Leader and Training
Pillar Leader

TPM Promotions Head, April, 2019

Model Line Members & AM
Pillar Leaders

TPM Promotions Head & April, 2019

AM Pillar Leaders
TPM Promotions Head & May, 2019
AM Pillar Leaders
TPM Promotions Head & June, 2019
AM Pillar Leaders
TPM Promotions Head & September, 2019
AM Pillar Leaders
TPM Promotions Head & November, 2019
AM Pillar Leaders

TPM Promotions Head, FI May, 2019

Pillar Leader & Training
Pillar Leader

TPM Promotions Head, FI August, 2019

Pillar Leader

TPM Consultant and August, 2019

Finance
TPM Consultant August, 2019

TPM Consultant September 2019 to

Awards Preparation

TPM Promotions Head, AM August, 2019

Pillar Leader
TPM Promotions Head, AM August, 2019
Pillar Leader
TPM Consultant & Training October, 2019
Pillar Leader
TPM Consultant & Training October, 2019
Pillar Leader
TPM Consultant End of Year 2

TPM Promotions Head and Q4 of Year 3

AM Pillar Leader
TPM Promotions Head and August, 2019
PM Pillar Leader
TPM Promotions Head and August, 2019
PM Pillar Leader
TPM Promotions Head, PM May, 2019
Pillar Leader & Training
Pillar Leader
TPM Promotions Head, PM June, 2019
Pillar Leader & Training
Pillar Leader
TPM Promotions Head, PM June, 2019
Pillar Leader & Training
Pillar Leader
TPM Promotions Head, PM July, 2019
Pillar Leader & Training
Pillar Leader
TPM Promotions Head and August, 2019
T&E Pillar Leader
TPM Promotions Head and August, 2019
T&E Pillar Leader
PM Pillar Leader, Steering May, 2019
Com
PM Pillar Leader, Steering Model Line Members:
Com (May - June, 2019)
Roll Out: January 2020

PM Pillar Leader, External Model Line Members:

Trainers (ex. Dual Tech. etc., (May - July, 2019)
Petron, Equipt Suppliers) Roll Out: January 2020

PM Pillar Leader, External Model Line Members:

Trainers (ex. Dual Tech. etc., (July - October, 2019)
Petron, Equipt Suppliers) Roll Out: January 2020

TPM Promotions Head and August, 2019

EEM Pillar Leader
TPM Promotions Head and August, 2019
EEM Pillar Leader
TPM Promotions Head and January, 2020
T&E Pillar Leader
TPM Promotions Head and January, 2020
T&E Pillar Leader
TPM Promotions Head, PM February, 2020
Pillar Leader and AM Pillar
Leader
EEM Team March, 2020
EEM Team July, 2020
TPM Promotions Head and July, 2020
QM Pillar Leader
TPM Promotions Head and July, 2020
QM Pillar Leader
TPM Promotions Head and July, 2020
QM Pillar Leader
TPM Promotions Head and August, 2020
QM Pillar Leader
TPM Promotions Head and August, 2020
QM Pillar Leader
TPM Promotions Head and September, 2020
QM Pillar Leader
FI, AM and PM Pillar September, 2020
Leaders
FI, AM and PM Pillar November, 2020
Leaders
TPM Promotions Head and April, 2019
OTPM Pillar Leader
TPM Promotions Head and April, 2019
OTPM Pillar Leader
Department Heads
TPM Promotions Head and May, 2019
T&E Pillar Leader
Department Heads May, 2019
Department Heads June, 2019
TPM Promotions December, 2019
Head,OTPM Pillar Leader
and T&E Pillar Leader
TPM Promotions Head, FI January, 2020
Pillar Leader and Finance
TPM Promotions Head and August, 2019
SHE Pillar Leader
TPM Promotions Head and August, 2019
SHE Pillar Leader
SHE Pillar Team August, 2019
SHE Pillar Team September, 2019

SHE Pillar Team, Engineerin October, 2019

SHE Pillar Team January, 2020
SHE Pillar Team April, 2020
SHE Pillar Team and June, 2020
Department Heads
TPM Consultant and Pillar October 2020 to February
Leaders 2021
TPM Consultant and Pillar October 2020 to April
Leaders, Department Heads 2021
and Line Leaders