Lorraine Fraser, P.Eng., M.Eng., MBA, CQE, CQA, CQM/OE, CSSBB ASQ Toronto Section – November 11, 2015

 Introduction To TPM  Benefits of TPM  What does TPM look like?  How to implement TPM  How to Sustain TPM  Summary  Questions TPM

The 7 Wastes

 TPM stands for Total Productive Maintenance.  TPM Development was first published in Japan in Since then new concepts and refinements have been added to the basic program.  TPM first took root in the automotive industry. More recently it has been introduced in consumer goods, electronics, plastics and many others.  Administrative and support departments such as product development and sales also use TPM.  Production output and rate, quality, safety, and the environment depend almost entirely on the state of equipment.  TPM is a method for continuously improving the effectiveness of production equipment and processes. TPM

World Class Operating Excellence is Achieved using optimized work standards with group activities of associates who demonstrate ownership 5S & Teams SafetyQualityCostProductivityPeople Focused Improvement Autonomous Maintenance Logistics Office Quality Management Training & DevelopmentEarly Equipment Management Planned Maintenance Environment, Health & Safety

TPM  Guarantees Significant Tangible Results - Results achieved include – reduction in equipment breakdowns, lower quality defects and claims, higher productivity, shrinking inventory, lower number of accidents. P… net productivity up by 2x Q…process defect rate down 90% C…production costs down 30% D…production and work in process inventories halved S…accidents 0 M…improvement suggestions up by 10x  Transforms the Plant Environment – a rusty plant can be reborn as a pleasant, saffe working environment.  Transforms the Employees - As concrete results are achieved, workers become motivated. Associates begin to think of TPM as part of their job.

Benefits of TPM TPM  Customers and visitors are impressed by these changes  Confidence in the plant’s products increases.  Overall Equipment Effectiveness (OEE) is maximized through zero breakdowns and failures, zero accidents, zero defects through total employee involvement.  Equipment reliability and maintainability as contributors to quality and productivity is increased.  TPM culture promotes zero loss activities.  TPM involves all associates from the shop floor to top management.

Benefits of TPM TPM

What Does TPM Look Like? TPM  Machine Operators are trained to do much of the maintenance operations, and it’s part of their Standard Work

What Does TPM Look Like? TPM  Necessary tools are readily available

What Does TPM Look Like? TPM  Equipment is modified such that it easy to keep clean, easy to see when maintenance is required. BeforeAfter

What Does TPM Look Like? TPM  Happy and Engaged Associates……

How To Implement TPM? TPM 1.Formally announce decision to introduce TPM. 2.Conduct TPM introductory education & publicity campaign 3.Create a TPM promotion organization. Plant Manager Section Managers Group Leaders Shop Floor Associates Companywide TPM promotion Committee Plant TPM Promotion Committee Section TPM Promotion Committee PM circles

How To Implement TPM? TPM Policy – example:  Establish a profitable corporate constitution, promote TPM Establish numerical goals – examples:  Zero breakdowns,  Zero defects, seek to maximize overall equipment effectiveness. 4. Establish basic TPM policy and goals.

How To Implement TPM? TPM 5. Draft a master plan for implementing TPM. To formulate a master plan for implementation decide what activities must be pursued to achieve the TPM goals. The core TPM activities are:  Focused improvement  Autonomous Maintenance  Planned Maintenance  Education and Training  Early Equipment Management  Quality Maintenance  Administrative and support department activities (Logistics & Office) 6.Kick off TPM initiative – should be designed to cultivate an atmosphere that raises morale and inspires dedication.

How To Implement TPM? TPM 7.Build a corporate constitution designed to maximize production effectiveness. 8.Build an early management system for new products and equipment. 9.Build a quality maintenance system. 10.Build an effective administration and support system. 11. Develop a system for managing health, safety, and the environment. 12. Sustain full TPM implementation and sustain levels. The first pillars to implement are the Focused Improvement, Autonomous Maintenance, Planned Maintenance, & Training and Development Pillars

How To Implement TPM? TPM

How To Implement TPM? TPM The Eight Major Plant Losses:  Shutdown loss  Production adjustment loss  Equipment failure loss  Process failure loss  Normal production loss  Abnormal production loss  Quality defect loss  Reprocessing loss  Loss deployment ◦ All pillars are responsible for analyzing the loss deployments for their losses. ◦ As losses are reduced, the priority of teams selected will change

How To Implement TPM? TPM

How To Implement TPM? TPM

How To Implement TPM? TPM

How To Implement TPM? TPM

How To Implement TPM? | TPM

How To Implement TPM? TPM 1. Select Equipment to work on…. Equipment that is giving you problems with… Unplanned downtime Excessive quality problems Excessive repair costs Premature “end of life” failures Running slower than “design” to prevent breakdowns 2. 5S Event…. Improve ability to perform regular inspections Allow the discovery of potential problems Log problems and potential problems and develop an immediate action plan Mark all lubrication, fluid connections and directions, etc Paint equipment

How To Implement TPM? TPM 3. Defining Machine Operator Tasks Develop Standards and Checklists – Cleaning, Lubrication, Visual Checks, Procedures to keep equipment new. 4. Make Machne Operator maintenance tasks easier/quicker Easy to see when things need to be maintained Lubrication needs become obvious to operator Routine cleaning operations easier Machine disassembly minimized Automate maintenance when possible Clear signals when maintenance is needed Ensure operator training is complete Finalize Checklist schedules

How To Implement TPM? TPM Define Maintenance Tech Tasks Provide Tech support to operator questions Provide clear communication path Spare Parts Program Equip Manufacturer recommendations Breakdown History Data Eliminate Equipment Deterioration Scheduled general inspections Equipment overhauls triggered by checklists Identify and Resolve Chronic Problems Breakdown history log Root cause analysis methods including 5 Whys

How To Implement TPM? TPM Define Maintenance Tech Tasks Develop and Analyze Equipment History Plot failure history Correlate with Equipment Quality Performance Determine Equipment Parameters That Predict Failure Use information from equipment manufacturer Oil, vibration, temperature analysis Develop Equipment Monitoring Systems Ensure appropriate accuracy and tolerance Lease equipment to ensure usability before purchase

How To Implement TPM? TPM

How To Implement TPM? TPM

Benefits of TPM TPM  Reactive Maintenance – if it is not broken do not fix it.  Preventive Maintenance – time or machine cycle based maintenance functions  Predictive Maintenance – functions on feedback that something needs to be done.  TPM – Autonomous Maintenance & Planned Maintenance

 Loss methologies in use: ◦ Use of a QA Matrix which is a tool that prioritizes actions against the sources of defects in a process. The matrix correlates defect modes with machine parameters. The matrix identifies the location of ‘Q’ points – the points that need to be controlled to eliminate defects. ◦ Defect Reduction Methodology ◦ CpK Improvement Methodology

How to Sustain TPM? TPM  Measuring progress is key (through Steering Committee)  The Primary Measurement tool is OEE (Overall Equipment Effectiveness is measures…. OEE = Equip Availability X Performance Efficiency X Quality Rate  Build strong teams at every level and staff a promotion office  Track projects weekly from date of closure, up to 6 months then monthly for the next 6 months. When a project looses traction, the pillar team analyzes the anomaly & take corrective actions as needed. Once a project is sustained for a year, it can be removed from the KPI tracker.  Use management indicators that show everyone (at every level) what concrete progress is being made and motivate their continued involvement.

How to Sustain TPM TPM  Recognized as the Global leaders in TPM  Two audits take place with Japanese auditors  In the face of growing competition, the award drives a continuous culture of improvement the focuses on cost reduction & improvement in efficiencies

Summary TPM

 TPM is a method for continuously improving the effectiveness of production equipment and processes by improving ‘On Demand’ availability of the equipment, through improved maintenance.  The primary focus is on involving machine operators in routine maintenance, and making that maintenance easily seen, easily done, and effective. This only happens through involvement of every single associate in every department in a factory. Summary TPM

Questions TPM