Laura Dietrich: Maintenance Manger Antoinette Lockett: Plant Manger Waseem Manzoor: Quality Manger Xiaoyan Liu: Production Manger.

Slides:



Advertisements
Similar presentations
Airbus Production System
Advertisements

TOTAL PRODUCTIVE MAINTENANCE.
Total Productive Maintenance
Total Productive Maintenance
Stability Tools TPM What is TPM ?
Total Productive Maintenance and FTM From Werardt
Welcome to our Presentation
In order to understand anything, you must not try to understand everything Aristotle.
Overall Equipment Effectiveness (OEE) 1 OVERALL EQUIPMENT EFFECTIVENESS (OEE) Factory Pulse Logix Automation Systems Pvt. Ltd.
Overall Equipment Effectiveness (OEE)
- Overall Equipment Effectiveness -
Productive Maintenance
Suggestion Schemes (contd…) Prepared by: Bhakti Joshi Date: February 21, 2013.
WHAT IS TPM. W H A T I S TPM ? A well defined methodology to optimize resources & improve performance A culture change - “never be satisfied” Team-work.
Total Productive Maintenance (TPM)
Total Productive Maintenance
TOTAL PRODUCTIVE MAINTENANCE
Total Production Maintenance (TPM)
Total Productive Maintenance Chit Khin TEC Introduction Good maintenance is fundamental to productive maintenance. TPM keep plant and equipment.
Total Productive Maintenance OVERVIEW. Target Audience : Senior Management Purpose of Module : To understand the need for TPM and the commitment required.
Total Productive Maintenance
Total Productive Maintenance (TPM)
Page. 1 Partners for Creative Solutions, Inc. 36 Deerfield Rd, Shrewsbury, MA Total Productive Maintenance.
Cost of Quality - COQ MGMT-5060 Operations Management.
1 Maintenance Performance Measures Management needs information of maintenance performance for planning and controlling the maintenance process. The information.
Productivity and Quality Management Lecture 11.
Chapter 16 Selling the Layout. Objectives After reading the chapter and reviewing the materials presented the students will be able to: Develop an appropriate.
McGraw-Hill/Irwin © 2003 The McGraw-Hill Companies, Inc., All Rights Reserved. 1 LEAN SYSTEMS TOOLS AND PROCEDURES.
Total Productive Maintenance (TPM)
TPM is a new technique of equipment maintenance that strives to achieve perfect production:  No Breakdowns  No Small Stops or Slow Running  No Defects.
1 Implementing a Business Management System compliant to ISO 9001:2000.
Trial & Prove The RouteMilestones 1-4 SM ‘Buy-in’ W/S 4 Day Launch Workshop/ Initial Training POLICY DEVELOPMENT & DEPLOYMENT Pilot Projects, Plant Clear.
1 Total Productive Maintenance and Maintenance Management
Niblock & Associates, LLC ©2010 Niblock & Associates, LLC Christian M. Paulsen 1.
Total quality management
TPM and Manufacturing Agility
Lorraine Fraser, P.Eng., M.Eng., MBA, CQE, CQA, CQM/OE, CSSBB ASQ Toronto Section – November 11, 2015.
Modern Maintenance. Management
Introduction to OEE (Overall Equipment Effectiveness)
KANZEN INSTITUTE ASIA PACIFIC 1 What is OEE ? OEE Overall Equipment Effectiveness Why is a high OEE important for the department ? OEE Calculation How.
TOTAL PRODUCTIVE MAINTENANCE CONCEPTS 29 TH JANUARY 2011 RM PERIYANNAN MANAGER(MECHANICAL) SERVICES MECHANICAL.
TOTAL PRODUCTIVE MAINTENANCE
Reactive to Proactive Maintenance through LEAN. What is Reactive, Proactive and Lean?
WORK STUDY HOW THE TOTAL TIME OF A JOB IS MADE UP (IE411)
Productivity and Quality Management Lecture 12.
Historical Philosophies of Quality 1. The Quality Gurus Quality Gurus – Individuals who have been identified as making a significant contribution to improving.
DOWNTIME Planned Maintenance Technique. TRAINING OVERVIEW.
Semester 8th (Self Support)
TOTAL PRODUCTIVE MAINTENANCE
IENG 451 / 452 Stability: Total Productive Maintenance
Total Productive Maintenance and Maintenance Management
TPM TPM is a productive maintenance implemented by all employees in an organization. TPM involves everyone in the organization from operators to senior.
TOTAL Productive MAINTENANCE
Total Production Maintenance (TPM)
Total Productive Maintenance
Dr. S. Poornachandra Dean EIE & BME SNS College of Technology
IMPLEMENTATION OF EIGHT PILLARS THE TOTAL PRODUCTIVE MAINTENANCE AT WATER SUPPLY COMPANY Iswandi Idris Ibrahim Ruri Aditya Sari.
Total Productive Maintenance and Quick Changeover
Operations Management
Total Productive Maintenance © Imants
TPM Definitions Goals and Benefits Components GEOP 4316.
PDT 319 Maintanance Management Total Productive Maintenance.
Operations Management
4/29/2019 Overall Equipment Effectiveness (OEE) “Strategic Management is an exciting process that allows an organization to be proactive rather than.
TOTAL PRODUCTIVE MAINTENANCE
Operations Management
5/10/2019 Overall Equipment Effectiveness (OEE) “Strategic Management is an exciting process that allows an organization to be proactive rather than.
HISTORY OF MAINTENANCE
1 TPM (Total productive maintenance). 2 TPM DEFINITION OF TPM Promoting PM by motivation management, namely by autonomous small group activities TPM is.
LEAN Principles Total Productive Maintenance (TPM)
Presentation transcript:

Laura Dietrich: Maintenance Manger Antoinette Lockett: Plant Manger Waseem Manzoor: Quality Manger Xiaoyan Liu: Production Manger

Meeting Agenda I.Understanding Downtime -Group II.Major Losses of TPM -Antoinette Lockett I.Planned Downtime Losses -Xiaoyan Liu II.Unplanned Downtime Losses -Laura Dietrich III.Reduce Speed Losses- IV.Poor Quality Losses -Waseem Manzoor III.Total Productive Maintenance I.What is TPM -Antoinette Lockett II.Breakdown of TPM -Laura Dietrich III.TPM History -Laura Dietrich IV.TPM Evolution V.Goal of TPM -Antoinette Lockett VI.Three Principles of Prevention

Meeting Agenda Cont. I.TPM-8 Pillars-Laura Dietrich II.Kick off TPM I.Launching TPM- Preparatory Stage-Antoinette Lockett II.Autonomous Maintenance- Xiaoyan Liu III.Equipment Management Life Cycle- Xiaoyan Liu IV.TPM Implementation-Waseem Manzoor V.Launching TPM- Stabilization-Waseen Manzoor VI.Eliminating Equipment Losses-Laura Dietrich VII.Improvement Goals for Chronic Losses-Laura Dietrich III.Overall Equipment Efficiency I.What is OEE-Xiaoyan Liu II.OEE Factors-Xiayon Liu III.Calculating OEE-Waseem Manzoor IV.TPM Benefits-Xiaoyan Liu

Understanding Downtime

MAJOR LOSSES

Planned Downtime losses Start-ups shift changes coffee and lunch breaks planned maintenance shutdowns

Unplanned Downtime Losses Equipment breakdown Changeovers Lack of material

Reduced Speed Losses Idling and minor stoppages Slow-downs

Poor Quality Losses Process non-conformities Scrap

TPM

What is Total Productive Maintenance? TPM is a plant improvement methodology which enables continuous and rapid improvement of the manufacturing process through use of employee involvement, employee empowerment, and closed-loop measurement of results

TOTAL = All encompassing by maintenance and production individuals working together PRODUCTIVE = Production goods and services that meet or exceed customers’ expectations MAINTENANCE = Keeping equipment and plant in as good as or better than the original conditions at all times Breakdown of TPM

TPM - History Productive maintenance (PM) originated in the U.S. in late 1940’s & early 1950’s Japanese companies modified and enhanced it to fit the Japanese industrial environment The first use the term TPM was in 1961 by Nippondenso, a Japanese auto components manufacturer Seiichi Nakajima – head of JIPM, one of the earliest proponents, known as the Father of TPM

TPM - Evolution Breakdown maintenance Preventive maintenance (PM) Productive maintenance Total productive maintenance

Goals of TPM 1. Aims at getting the most effective use of equipment 2. Builds a comprehensive PM system 3. Brings together people from all departments concerned with equipment 4. Requires the support and cooperation of everyone from top managers down 5.Promotes and implements PM activities based on autonomous small group activities. 6.Maintaining Equipment for life 7.Encouraging input from all employees 8.Using teams for continuous improvement

Three Principles of Prevention Maintenance of normal conditions Early discovery of abnormalities Prompt response

TPM 8 PILLARS

PILLARS OF TPM Kobetsu KaizenPlanned MaintenanceQuality Maintenance Training Office TPM Safety, health and Environment 5s Autonomous Maintenance

Kick off TPM

Launching TPM- Preparatory Stage Announce top management’s decision to introduce TPM Launch an educational campaign to introduce TPM Create an organizational structure to promote TPM Establish basic policies Form a master plan for implementing TPM

Launching TPM- Preliminary Implementation

Improve the effectiveness of each critical piece of equipment Set up and implement autonomous maintenance Establish a planned maintenance system in the maintenance department Provide training to improve operator and maintenance skills Develop an early equipment management program Launching TPM- TPM Implementation

Perfect TPM implementation and raise TPM levels Launching TPM- Stabilization

Eliminating Equipment Losses

Improvement Goals for Chronic Losses

OEE

What is OEE OEE (overall equipment efficiency) is a “best practices” way to monitor and improve the efficiency of your manufacturing processes –machines –manufacturing cells –assembly lines

OEE Factors Plant Operating Time Planned production time –planned downtime ie. breaks Availability –downtime losses Performance –Speed losses Quality –Quality losses

World Class OEE

Calculating OEE Availability = Operating time/planned production Performance = Ideal Cycle Time / Total Pieces or (total pieces / Operating time)/Ideal Run time Quality = Good Pieces / Total Pieces OEE = Availability X Performance X Quality

Example OEE Calculation

Availability = Operating time Planned production time = 373 minutes / 420 minutes = (88.81%)

Performance = (Total pieces /Operating time) Ideal Run Time = (19,271 pieces/373 minutes)/60 pieces per minute = (86.11%)

Quality = Good Pieces Total Pieces = 18,848 / 19,271 pieces = (97.80 %)

OEE = Availability X Performance X Quality = X X = (74.79%)

TPM BENIFITS

TPM - Benefits Improved equipment eliminates the root cause of defects Defects are prevented through planned maintenance Preventive maintenance costs are reduced as equipment operators conduct autonomous maintenance Improved equipment designs ensure that new equipment naturally produces fewer defects Simplified products designs and a redesigned process produce with few defects Engineers, technicians and managers are trained in maintenance and quality

TPM - Benefits (Japanese TPM Prize winners during ) Equipment failures reduced from 1,000/month to 20/month Quality defects reduced from 1.0% to 0.1% Warranty claims reduced by 25% Maintenance costs reduced by 30% WIP decreased by 50% Productivity improved by 50%. (Patterson & Fredendall, 1995)

TPM – Success stories USPS Albany, New York: annual save of $86,000; could save $4.5 million if applied nationwide Yamato Kogyo Corp., Japan: - productivity up by 130%, - accidents cut by 90%, - defects reduced by 95%, - employee suggestion rate increased by over 300%