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 and cross functionality Transparency and visibility Discipline and rigour Continuous improvement Wireless real time data collection, data mining and data assessment
TPM is a system to organize practical, shop-floor methods to reduce losses... EQUIPMENT 1- Failure Loss 2- Start up Loss 3- Speed Loss 4- Set up & Adjustment 5- Idling & Minor Stops 6- Defects & Rework 7- Shutdown Loss 8- Die, Jig & Tool Loss MAN POWER 10- Motion Loss 11- Measure & Adjust 12- Management Loss 13- Line Organisation 14- Lack of Automation ENERGY 9- Energy Loss MATERIAL 15- NTM, Consumables 16- Yield Loss 16 MAJOR LOSSES
Machine efficiency Operational timeWorking time Man Loading Time Machine Loading time Net operational time Operational time Real working time Net operational time Man (Man time) Machine (machine time) Energy input Material input (number, weight) Effective energy N. quality products Value added time Value added time Ideal weight of quality products Production man-hour loss Line organisation man-hour loss Scheduled Downtime Downtime loss Performance loss Defects quality loss EnergyMaterial Defect in man-hour loss 5 major losses obstructing manpower efficiency major losses obstructing equipment efficiency Labour efficiency
W H A T I S TPM ? in other words : INCREASE THE RELIABILITY OF THE PLANT
- Cleaning - Tagging - 5 S - Details: 1 / 30 / Teams - Loss Deployment - Audits - Communication : Boards - One Point Lessons (OPL) T E C H N I Q U E S o f TPM
Losses Innovation area to achieve optimal conditions Sporadic loss Time Restoration area in order to return to previous condition “Quick-fix zone” Chronic losses Objective Optimal conditions Zero defects EXIT THE “QUICK-FIX CULTURE” C U L T U R E C H A N G E
COMPANY LANGUAGES Source : Juran Man (Man time) Machine (machine time) Top Management Language $ $ AND TECHNICAL Middle Management Language $ Junior Management and personnal Language TECHNICAL TPM CAN SPEAK ALL COMPANY LANGUAGES
TPM ORGANISATION Man (Man time) $ AM PILLAR PM PILLAR FI PILLAR Machine (machine time) OVERALL WCMCOORDINATOR BOARD Machine (machine time) PLANT WCM COORDINATOR TPM TEAM STRUCTURE AREA COMMITTEE STRUCTURE DEPARTMENTAL COMMITTEE STRUCTURE PLANT STEERING COMMITTEE STRUCTURE AM=AUTONOMOUS MANAGEMENT PM= PROGRESSIVE QUALITY FI=FOCUSED IMPROVEMENT
LOSS DEFINITION Actual Cost Losses Cost that can be attacked Cost that can not be attacked Cost that Adds Value
LOSSES OF UPTIME AVAILABILITY LOSSES PERFORMANCE LOSSES QUALITY LOSSES BREAKDOWNS START UP SIZE/ BRAND CHANGE SPEED LOSSESSHORT STOPS DEFECTSSCRAPSOVERUSAGE LOSSES OF UPTIME PLANNED MAINTENANCE TEAMS FOCUSED IMPROVEMENT TEAMS AUTONOMOUS MANAGEMENT TEAMS PROGRESSIVE QUALITY TEAMS These teams attack individual loses with different methodologies
100 % LOSS DEPLOYEMENT OF UPTIME (OEE) Waste Losses: Speed Losses: Hold Losses: Size Brand Change Startup Losses: Availibility Losses: Performance Losses: Quality Losses: UPTIME Breakdown Losses: Short Stops: UPTIME IS AN INDICATION ON ‘’WHAT WE DO GOOD’’ THE PORTION ABOVE UPTIME THAT SUMS UP TO 100 % SHOWS THE LOSSES LOSSES NEEDS TO BE DEFINED AND DEPLOYED SYSTEMATICALLY FOR GOOD ANALYSIS