Slide 1 T otal P roductive M aintenance TPM Overview Dave Hoyte, CEO JL French Corporation

Slide 2 TPM as a Lean Initiative Competitive costs require –Spending control –Defect control –Downtime reduction TPM = Total Productive Maintenance –Proactive (with all employees involved) –Preventive –Predictive –Planned

Slide 3 Why Change? ACTIONS: –Reduce defectives / scrap –Reduction of lost production time –Lowest possible cost by reducing waste

Slide 4 Lean System 5S Visual Factory T P M Standardized Work Leadership by Example & Commitment In-Station Process Control Lean Measures Employee Involvement & Mutual Respect Pull system / flow production Peak Performance Variation reduction / Six Sigma Continuous Waste Reduction Rapid Changeover / Customer-driven lot size

Slide 5 7 Wastes T ransportation E xcess production A dded processes M otion W aiting I nventory N on-conformance (defectives)

Slide 6 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 Defectives - Rework or Replace –Incapable processes or process not compatible with customer expectations or design spec (design for mfg) –Tooling condition –Operator methods and errors

Slide 7 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 Defectives - Rework or Replace –Incapable processes or process not compatible with customer expectations or design spec (design for mfg) –Tooling condition –Operator methods and errors

Slide 8 Effective TPM Eliminates 5 Losses 1.Equipment breakdowns 2.Defects, scrap, and rework 3.Safety Issues 4.Mini stoppages 5.Reduced speed

Slide 9 What is TPM?? 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 TPM is a Lean tool to optimize the effectiveness of manufacturing equipment and tooling.

Slide Operator Autonomous Maintenance Countermeasures for Contamination Initial Standards General Inspection Autonomous Inspection Standardization Aut. Mgt. Seven Steps of TPM Initial Clean-up

Slide 11 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 12 5S 5S Workplace  S ort  S ort (organize)  S hine  S hine (clean)  S et in order  S et in order (make orderly and neat)  S tandardize  S tandardize (visual place for everything)  S ustain  S ustain (maintain the system ) A safe, clean, orderly workplace is fundamental to quality, efficiency, and teams

Slide 13 TPM starts with 5S You can’t 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

Slide 14 Downtime Visual Controls Visual or audio alerts –Abnormality obvious at a glance (e.g. stoppage, reject, control fault) –Alerting Maint and team leaders –Provide real time “scoreboard” for employees Machine down light visible from aisle Production status board (e.g. actual counts vs. goal) Scrap counts and downtime minutes Located in clear view in shop (not in control room) Simple, self regulating, & employee managed

Slide 15 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 16 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 Subcategories for Tooling (e.g.) –Slides –Cores –Inserts –Ejector pins Subcategories for Other (e.g.) –Operator error –Materials

Slide 17 Minimum Downtime Tracking Equip Tools Other

Slide 18 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 19 Predictive Maintenance Tools Rate/hr vs. target or historical normal output (B/W) Database –MP2 / maintenance history –statistical probability (frequency & duration) Physical prediction of impending failure –Sound (bearing) –Temperature (cooling water) –Flash (core pins) –Shot monitoring system –SPC on part geometry –Hydraulic pressure (ejector pins) –Spindle loads (amps) –Fluids / Lubrication analysis (milipore) –Vibration Signature Analysis

Slide 20 Preventive Maintenance System History of downtime by major machine & tool –Downtime measurement & tracking –Mean Time Between Failures –Average downtime –Pareto of causes at component level (eg L/S or temp sensor) –Cost to maintain Develop PM cards based on frequency of failure and magnitude of average lost time (start small & grow) –Limit & prox switches –Shot tip / sleeve –Critical frame and cylinder mounting bolts –Expendable tools –Valves, hoses, packing, seals PM’s have instruction, schedule/frequency & sign-off –PM’s / repairs done in window of opportunity when machine is down –Cycle count or date based execution of PM’s (eg cutter change) –PM status visual (work completed / not completed)

Slide 21 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 One point lessons for operator awareness Creates OMP (Operator - Maintenance Partnership) Operator performs checks, problem solving, and improvements 5.Professional Maintenance

Slide 22 TPM Production Operators Clean & Check Observe Categorize Manufacturing Engineers Equipment Planning Equipment Studies Production Planning & Control Schedule P.M. Quality Engineers Standards & Calibrations Active Planned Maintenance Process

Slide 23 OMP - Operator Maintenance Partnership Operator training in TPM Operator basic equip inspection & tooling checks Operator basic cleaning Operator lubrication check One point lessons (capture knowledge) TPM Board & TPM Tags (proactive operator involvement) TPM

Slide 24 TPM Tag System Problem communication tool to and from maintenance, tool room, and production –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 TPM Tag used for recording problem & fix –Blue Tag-Operator or Maint responsible to repair –Red Tag- Safety-related request (priority)

Slide 25 Operator/SupervisorProduction ManagementMaintenance 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. 7. Operator/Supervisor check to see if work was done. 6.After work is completed, maintenance completes back side of A tag and places both the A & B tag in the work completed box 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. 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. Tag Process

Slide 26 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 27 Professional Maintenance Equip Safety Skill building Cross-training Area Maintenance WC MRO stores Maint Mgmt System Down alarms Radios Planned PM

Slide Operator Autonomous Maintenance Countermeasures for Contamination Prepare Temporary Standards General Inspection Autonomous Inspection Standardization Aut. Mgt. 7 Steps Initial Clean-up OIL T P M

Slide 29 TPM 5S TPM I Step 1 Step 2 Step 3 TPM II Step 4 Step 5 Step 6 Step 7 Initial Focus prerequisite for TPM I

Slide 30 STEP 3: Prepare Temporary Standards This step is to enhance the equipment reliability & maintainability. Temporary Check Sheet For Clean-Up, Lubrication, Start-up, and Shut-down: –What items need to be done –Who will perform the check –How often to check –Where the location is to be checked –What to use for the inspection or cleaning –Target time to complete the task

Slide 31 TPM Summary TPM = Total Productive Maintenance –Proactive (all employees involved) –Preventive –Predictive –Planned TPM is an integral part of JLF Total Quality production System 5S Visual Factory T P M Standardized Work Continuous Waste Reduction Peak Performance

Slide 32 TPM is a Lean tool for Quality and Productivity