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TPM
Overview
Dave Hoyte, CEO JL French Corporation
Slide 1
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Lean System
Peak Performance Pull system / flow production Rapid Changeover / Customer-driven lot size Continuous Waste Reduction Lean Measures
5S
Visual Factory
TPM
Standardized Work
Variation reduction / Six Sigma In-Station Process Control Leadership by Example & Commitment Employee Involvement & Mutual Respect
Slide 4
7 Wastes
Causes of Waste
Excess Manning
Poor layout and material presentation Rework and extra processes Inconsistent / inefficient work methods
Excess Downtime
Tooling condition Unreliable equipment Long changeovers Incapable process
Causes of Waste
Excess Manning
Poor layout and material presentation Rework and extra processes Inconsistent / inefficient work methods
Excess Downtime
Tooling condition Unreliable equipment Long changeovers Incapable process
1. 2. 3. 4. 5.
Equipment breakdowns Defects, scrap, and rework Safety Issues Mini stoppages Reduced speed
Slide 8
What is TPM??
TPM is a Lean tool to optimize the effectiveness of manufacturing equipment and tooling.
1. Starts with 5S / Visual Factory 2. Builds a comprehensive Downtime Database by cause, frequency, and duration 3. Predicts and prevents downtime by PM system 4. Expands role of Operator as first point of early warning and prevention 5. Develops Professional Maintenance skills
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7 7 6 6 5 5 4 4 3 3 2 2 1 1
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TPM is Planned, Predictive, & Preventive 1. Starts with 5S / Visual Factory 2. Builds a comprehensive downtime data base by cause, frequency, and duration 3. Predicts and prevents downtime by PM system 4. Expands role of Operator as first point of early warning and prevention 5. Professional Maintenance
Slide 11
5S Workplace
A safe, clean, orderly workplace is fundamental to quality, efficiency, and teams
Sort (organize) Shine (clean) Set in order (make orderly and neat) Standardize (visual place for everything) Sustain (maintain the system)
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TPM starts with 5S You cant see problems clearly when the workplace is in disarray Cleaning and organizing the workplace helps the team to uncover problems Making problems visible is the first step of improvement Clean machines and workplace create pride & Safety
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Downtime Database
Categorize at a minimum by Equip, Tooling, C/O, Other Segmented bar graph for E-T-O lost time Subcategories for Equip (e.g.)
Hydraulic / pneumatic Mechanical / lubrication Electrical / controls Shot-end components Slides Cores Inserts Ejector pins
Other Tools
Equip
Slide 17
TPM is Planned, Predictive, & Preventive 1. Starts with 5S / Visual Factory 2. Builds a comprehensive downtime data base by cause, frequency, and duration
Slide 18
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TPM
Production Operators Clean & Check Observe Categorize Production Planning & Control Schedule P.M.
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Identify abnormal machine conditions Record problem discovered by operator Record problem found during scheduled PM Status tracking system of requested repairs TPM visual management tool (hang tags) Repair history for future problem solving
Blue Tag-Operator or Maint responsible to repair Red Tag- Safety-related request (priority)
Slide 24
Tag Process
Operator/Supervisor 1. Abnormality Identified 2. Fill out Tag Red= Safety Blue= Prod/Maint 3. Hang C-tag as close to the defect as possible 4. Hang A &B Tags on the TPM Tag status board by Machine location and area of responsibility to correct. 5.Maintenance evaluates problem. If fixed immediately go to 6. If parts or time needed, maint pulls A tag from board. The A tag is MWO. The B tag is posted on the Maint WO status section of the TPM Board with est. timing. 6.After work is completed, maintenance completes back side of A tag and places both the A & B tag in the work completed box 9. Production management reviews the information. Also reviews the comments and takes actions if required. Places tag in history file box located in the office Tag information is recorded and reviewed for continuous improvement of PM database by Production and Maintenance; Repeat operator tags may indicate Maint needs to investigate.
Slide 25
Production Management
Maintenance
8. If OK, Operator/ supervisor removes C tag from machine and places ABC tags in Completed box. If not OK, tags stay and maint is contacted. Contact noted on tag.
TPM is Proactive, Predictive, Preventive & Planned 1. Starts with 5S / Visual Factory 2. Builds a comprehensive downtime data base by cause, frequency, and duration 3. Predicts and prevents downtime by PM system 4. Expands role of Operator as first point of early warning and prevention
5. Professional Maintenance
Slide 26
Professional Maintenance
Equip Safety Skill building Cross-training Area Maintenance WC MRO stores Maint Mgmt System Down alarms Radios Planned PM
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7 7 6 6 5 5 4 4 3 3 2 2 1 1
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OIL
General Inspection Prepare Temporary Standards Countermeasures for Contamination Initial Clean-up
TPM
Initial Focus
5S
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TPM Summary
TPM = Total Productive Maintenance
Proactive (all employees involved) Preventive Predictive Planned
Peak Performance
5S
Visual Factory
TPM
Standardized Work
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