1、,Welcome To,About T.P.M. After World War ll. Japanese industries determined that to complete successfully in the world market they had to improve the quality of their products. to do so, they imported management and manufacturing techniques from United States and adapted them to their circumstances.

2、 Subsequently, their products became known throughout the world for their superior quality, focusing world attention on Japanese- style management techniques. TPM DEVELOPMENT PROGRAM Implementing Total Productive Maintenance Seiichi Nakajima.,Definition of T.P.M : T.P.M. IS: A PRODUCTIVE MANUFACTURI

3、NG SYSTEM with the TOTAL Participation of: Managers, Supervisors, Engineers, Technicians and Operators. T.P.M. Includes the Following Benefits: Maximize Overall Equipment Effectiveness Establishment a Complete System of Maintenance for the Machine Entire Life Create a Better Work Environment, Promot

4、ing the Participation for All Employees,T.P.M. = Medical Science of Equipment,VIDEO-AUTO DIE-BONDER MODEL 8030A,PRODUCTION Foton AUTOMATION,POWER,HEATER,B-820,The Main objective of TPM is : Zero Interruptions Zero Defects Zero Accidents Throughout total employees participation from Top Management to

5、 Operators, based in the following activities: Autonomous Maintenance Planned Maintenance Individual Improvement Quality Maintenance Early Equipment Management Education/Training (People Development) Safety,PILLARS OF TPM,EXCELLENCE,People , Equipment and Product Improvement by Working Together.,T.P

6、.M.,Total Productive Manufacturing,PLANT OVERVIEW,PLANT OVERVIEW,TPM Self Assessment,PLANT OVERVIEW,TPM Self Assessment,TPM Self Assessment,1991 First attempt to implement TPM. TPM consultant provides training to selected Managers, Supervisors and Engineers. One coordinator with experience in Proces

7、s and Maintenance is assigned to lead TPM. Literature and materials, prepared and distributed. Lack of support and involvement results in failing the implementation.,Background:,One Staff Mgr. is assigned to lead the TPM Implementation plant wide. A core team is formed on 2Q/96 with key people from

8、different departments to coordinate the implementation. Model equipment is selected based on bottle neck operation. Equipment conditions analysis performed. Most of the teams cover the initial cleaning. Activities are focused on six big losses detected and 5 Ss implementation.,TPM Self Assessment,19

9、96,Asia Benchmarking,PLANT OVERVIEW,TPM Self Assessment,Asia Benchmarking,Facility 1April Facility 2May Facility 3 June Committee: 4 Chosen Folks Objective: Learn from Asia success experiences in TPM implementation and come up with directions for Plant implementation.,TPM Benchmarking Asia Facilitie

10、s,1996,Benchmarking Conclusions,Total management involvement. T.P.M. Manager (dedicated). A well defined implementation process. Provide people with time to work on it. ( 4- 6 Hr./wk ). Each staff has their own T.P.M. Promoter full time. Focused in Consultant X model. Focused in just one product lin

11、e per area. Budget assigned for consulting and external training.,TPM Implementation,PLANT OVERVIEW,TPM Self Assessment,Asia Benchmarking,TPM Implementation,IMPLEMENTATION/CONSULTANT,* Q3 1996, Consultant X is selected to be Consultant. * Training of Managers, Team leaders and Team members * Master

12、Plan Defined * TPM. implementation initiated according to Consultant X recommendations,# ESTABLISH AN INTEGRATED STRUCTURE TO PROMOTE T.P.M. AS A COMPANY CULTURE. # MAXIMIZE OVERALL EQUIPMENT EFFECTIVENESS # TOTAL EMPLOYEE INVOLVEMENT. # CULTIVATE EQUIPMENT & PROCESS RELATED EXPERTISE THROUGHOUT SHO

13、P FLOOR. ( Autonomous Maintenance, Planned Maintenance etc.) # ESTABLISH A RELIABILITY AND MAINTAINABILITY SYSTEM TO MAXIMIZE EQUIPMENT LIFE TIME. (Planned Maintenance Autonomous Maintenance, Individual Improvement, Early Equipment Management.) # ALL EMPLOYEES MUST PARTICIPATE IN T.P.M TRAINING PROG

14、RAM. # ALL AREAS MUST FOLLOW T.P.M. ESTABLISHED GUIDE LINES. # DEPARTMENT HEAD IS RESPONSIBLE TO ACCOMPLISH AND SUPPORT T.P.M. GOALS.,T.P.M. POLICY,T.P.M. PLANT WIDE STRUCTURE,TPM Responsible Plant Manager,5 s,T.P.M. Office,Autonomous Maintenance,Planned Maintenance,Individual Improvement,Quality Ma

15、intenance,Training People Development,Early Equipment Management,Safety,(OVERLAPPING SMALL GROUPS),PLANT MANAGER,TPM PILLARS & PROMOTION OFFICE,DEPARTMENT MANAGERS,TPM TEAM,DEPARTMENT SUPERVISORS,TPM PROMOTERS,PROMOTION STRUCTURE,TPM,T.P.M. IMPLEMENTATION ACTIVITIES,MANAGER TEAMS,Machine 2,Machine 4

16、,Machine 1,Machine 3,Line and Machine Selection,TPM Implementation Plan,Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2,1996 1997 1998 1999 2000,ACTIVITIES,PREPARATION STAGE,DEFINE STRATEGIES MASTER PLAN ORGANIZATION INTRODUCTION TRAINING PUBLICITY,MODEL MACHINES Machine 1 Machine 2 Machine 3 Machin

17、e 4,START,IMPLEMENTATION,EXTEND IMPLEMENTATION SIMILAR PRODUCTION LINES,TARGET,COMPLETE IMPLEMENTATION DEFINED AREAS,AUTONOMOUS MAINTENANCE & REDUCE 6 BIG LOSSES EXTEND SIMILAR MACHINES,1,2,3,30% to 50%,100%,TPM 90 Days Explosion Plan,October,November,December,ww40,ww41,ww42,ww43,ww44,ww45,ww46,ww47

18、,ww48,ww49,ww50,ww51,ww52,Machine 1,PILOT TEAM,Step 3,Start,Planned maintenance,Start,6 big losses,Start,Individual Improvement,Start,10 Extension teams,step 1-2,4 mc,3 mc,3 mc,19 Extension teams,Start step 1,7 mc,6 mc,6 mc,Machine 2,PILOT TEAM,Step 2-3,Start,Planned maintenance,Start,6 big losses,S

19、tep 1,Step 2,Individual Improvement,Step 1,11 Extension teams,step 1-2,B-613,3 mc,2 mc,2 mc,B-601,L-604,Machine 3,PILOT TEAM,Step 2-3,Start,Planned maintenance,Start,6 big losses,Start,Individual Improvement,Start,6 Extension teams,step 1-2,2 mc,4 mc,2 Extension teams,Start step 1,Start,Machine 4,PI

20、LOT TEAM,Step 1-2,Start,Planned maintenance,Start,6 big losses,Start,Individual Improvement,Start,4 extension teams,Start step 1,a-820,a-821,J-701,J-601,PILLARS,IMPLEMENTATION MODEL,GANTT,TPM Activity Board Extension Teams,Server Data collection,M1,M2,M3,M4,GM Audit,Team presentations,TPM Office Aud

21、it,Consultant visit,TPM Meeting,Local BOOT CAMP,TPM MCOE MEETING, JAPAN,Pillars meeting,T.P.M. TRANSITION CURVE,DENIAL,RESISTANCE,EXPLORATION,COMMITMENT,POLICIES DEVELOPMENT T.P.M. PROMOTION OFFICE START MANAGEMENT MACHINES FOCUS IN FEW EQUIPMENT FOCUS TRAINING SUCCESS STORIES 5 Ss,DEVELOP DATA COLL

22、ECTION SYSTEM ATTENTION TO FOCUS TEAMS TRAINING DEPLOYMENT IMPLEMENTATION PLAN RESOURCE IMPLEMENTATION,GOALS SETTING FOR ALL ORGANIZATION.,LOOK FOR ADDITIONAL WAYS TO DEPLOY T.P.M.,FINISH CONFLICT WITH THE CULTURE ORGANIZATION ALIGNMENT REWARD SYSTEM CONTROL CHAOS,T.P.M. PROMOTION DELEGATION INCLUDE

23、 T.P.M. IN PERFORMANCE MANAGEMENT PLAN. INCLUDE T.P.M. IN JOB DESCRIPTION. ACCELERATED DEPLOYMENT.,CONSULTANT OUT,CONSULTANT IN,KICK OFF,1.- TOTAL EQUIPMENT EFFECTIVENESS % 85 A) Equipment Breakdown HOURS/MONTH 1/10 B) M.T.B.A. MINUTES 1x10 x C) M.T.B.F. HOURS 1x2x 2.- REJECT CAUSED BY LINE EQUIPMEN

24、T PPM 1/5 3.- LINE REJECT RATE % 1/5 4.- CYCLE TIME DAYS 0.8X 5.- FATAL ERROR AT CUSTOMER # OF 0 6.- ON TIME DELIVERED % 98 7.- MANUFACTURING COST USD 20% LESS 8.- LABOR PRODUCTIVITY K.UNITS /# OF D/L 2X,KEY GOALS,AUTONOMOUS MAINTENANCE IS:,Maintenance performed by equipment operators.,AUTONOMOUS MA

25、INTENANCE,Step # 1,Initial Cleaning,1,3,4,5,6,7,8,2,Photos Before Photos After,Initial Cleaning (Inspection),Put F Tags,Major Problems Selection,Formats: Daily Cleaning & Initial Inspection Hot Spots, CAP-DO 5Ws,Develop One Point lesson,Standardization Cleaning / Lubrication,Training in One Point Le

26、sson,AUTONOMOUS MAINTENANCE,AUTONOMOUS MAINTENANCE,2,3,Tentative Standards,1,7,6,5,3,8,2,Develop tentative standards,Cleaning / Lubrication implementation,Put “F” Tags (Establish time & frequency),Improve time of execution,Remove “F” Tags,Detail activities,Apply activities to similar machines,Step #

27、 3,Verify actual time Vs estimated,4,TPM Teams Status,October 1997,Number of Hot Spots detected: 284 Number of Hot Spots solved: 126 One Point Lesson developed: 44 One Point Lesson Taught: 34 Number of teams on TPM: 27 Teams on step 3: 1 Teams on step 2: 2 Teams on step 1: 24,PLANT OVERVIEW,TPM Self Assessment,Asia Benchmarking,TPM Implementation,Expansion Plan,Expansion Plan,T.P.M. DEPLOYMENT,LINE FLOW,1997,1998,CURRENT EQUIPMENT IN T.P.M.,SAME KIND OF EQUIPMENT,1999/2000 EXP