PLANNED MAINTENANCE ACTUAL CASE STUDY AMKOR / ANAM

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Presentation transcript:

PLANNED MAINTENANCE ACTUAL CASE STUDY : @ AMKOR / ANAM Graph below shows actual results on the number of breakdowns after thorough implementation of Planned Maintenance 4 Phases To Zero Breakdown Sep-00 Oct-00 Nov-00 Dec-00 Jan-01 Feb-01 Mar-01 Apr-01 May-01 Jun-01 Jul-01 Aug-01 Sep-01 PLAN 259 200 150 100 85 50 25 10 ACTUAL 237 151 117 80 33 28 13 12 15 6 4 1st PILOT BDO TRENDING FOR PM PILOT MACHINES BDO 250 300 STEP 1 STEP 2-3 22 MACHINES STEP 4 LEGEND : BDO - Number of Breakdown Occurrences

WHAT TPM WILL ACHIEVE ? MRC Bearings reduced unplanned downtime by 98% in one cell and 99% in another -all within one year. Monsanto runs their three-year old TPM start-up plant at 97% on-stream time while most other units run between 85% and 90. 3M reduced their maintenance cost by 60% within three years. DuPont reduced off-quality by 69% and improved capacity by 29% in three years. Texas Instruments reduced their off-quality by 50% in their Philippines plant. Harley-Davidson estimates that the ROI from TPM has been ten-fold their cost of implementation. Whirlpool improved OEE by 21%.