Total Productive Maintenance

TPM
Overview
Dave Hoyte, CEO
JL French Corporation

Slide 1

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 2

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

Slide 3

Lean System
Peak Performance
Pull system / flow production
Rapid Changeover / Customer-driven lot size
Continuous Waste Reduction
Lean Measures

5S
Visual
Factory

TPM

Standardized
Work

Variation reduction / Six Sigma

In-Station Process Control
Leadership by Example & Commitment
Employee Involvement & Mutual Respect
Slide 4

7 Wastes

Transportation
Excess production
Added processes
Motion

Waiting
Inventory
Non-conformance (defectives)
Slide 5

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 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

Effective TPM Eliminates 5 Losses

1.
2.
3.
4.
5.

Equipment breakdowns
Defects, scrap, and rework
Safety Issues
Mini stoppages
Reduced speed

Slide 8

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

Slide 9

Operator Autonomous Maintenance

Seven Steps
of TPM

Aut. Mgt.
Standardization
Autonomous Inspection

General Inspection
Initial Standards
Countermeasures for Contamination
Initial Clean-up

77
66
55
44
33
22
11
Slide 10

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 11

5S Workplace
A safe, clean, orderly workplace is
fundamental to quality, efficiency, and teams

Sort (organize)
Shine (clean)
Set in order (make orderly and neat)
Standardize (visual place for everything)
Sustain (maintain the system)
Slide 12

TPM starts with 5S

You cant 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 13

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 14

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 15

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 16

Minimum Downtime Tracking

Downtime by Cause 3500 ton Bay
(avg min/shift per Machine)

Other
Tools

120
100
80
O

Minutes 60

40

Equip

20
0

1Q02 2Q02

Jun

Jul

Aug

Sep

Oct

Nov

Dec

Slide 17

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 18

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 19

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
PMs have instruction, schedule/frequency & sign-off
PMs / repairs done in window of opportunity when machine is down
Cycle count or date based execution of PMs (eg cutter change)
PM status visual (work completed / not completed)
Slide 20

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 21

TPM
Production Operators
Clean & Check
Observe
Categorize
Production Planning
& Control
Schedule P.M.

Active
Planned
Maintenance
Process

Quality Engineers
Standards &
Calibrations

Manufacturing Engineers
Equipment Planning
Equipment Studies

Slide 22

OMP - Operator Maintenance Partnership

Operator training in TPM

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)

Slide 23

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 24

Tag Process
Operator/Supervisor

Production Management

Maintenance

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.
Slide 25

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 26

Professional Maintenance

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

Slide 27

Operator Autonomous Maintenance

7 Steps
T P M

Aut. Mgt.
Standardization
Autonomous Inspection

OIL
General Inspection
Prepare Temporary Standards
Countermeasures for Contamination
Initial Clean-up

77
66
55
44
33
22
11
Slide 28

TPM
Initial Focus

5S

TPM I
Step 1
Step 2
Step 3

TPM II
Step 4
Step 5
Step 6
Step 7

prerequisite for TPM I

Slide 29

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 30

TPM Summary
TPM = Total Productive
Maintenance
Proactive (all employees
involved)
Preventive
Predictive
Planned

TPM is an integral part

of JLF Total Quality
production System

Peak Performance

Continuous Waste Reduction

5S
Visual
Factory

TPM

Standardized
Work

Slide 31

TPM is a Lean tool for

Quality and
Productivity

Slide 32