UK TPM Seminar

TPM in the connected factory

Dec. 201６
Japan Institute of Plant Maintenance
Senior Researcher
Zensuke (Zen) Matsuda

1
 TPM
T….. Total Humanity
P….. Productive Preventive Zero loss
M…. Maintenance Sustainability
Management Actual Scene/Thing Rejuvenation

TPM is the holistic, structured and quantifiable

methodology to seek productive excellence by
eliminating losses. TPM is a concept rejuvenating
itself with experience of many users.

2
 History of TPM
1950 1960 1970 1980 1990 2000 2010

Breakdown Maintenance
1951 Preventive Maintenance
1960 Productive Maintenance
Preventive
1971 TPM (Total Productive Maintenance)
1982 TPM (Company- wide)
Operator Participated
2000 TPM(21st Century)
Entire Company

Innovative

3
Awarded factory / Industrial Classification
Machine work & Assembly Industry 1,341 Process Industry 1,838
Automobile and Other Motor Vehicle 123 Iron and Steel & Non-Ferrous Metal 221
Products
Automotive Parts & Accessories, and 642 Chemicals 335
Transportation Equipment
General Industrial Machinery & Equipment, 127 Textiles 84
Precision Apparatus
Semiconductor & Electronic Equipment 213 Rubber & Plastic Products 196
Consumer Electronic Appliances, 99 Food & Beverage 503
Information Communication Electronics
Equipment
Fabricated Metals 103 Drug & Medicine 26
Housing & Woodwork 34 Pulp & Paper 166
Printing 98

Cement & Ceramic Products 93

Electric Power & Gas, Petroleum and Coal 118

Others 70
Year : 1971-2015 Total 3,249.
4
 TPM Awards to Tetra Pak
Tetra Pak Home Page :Tetra Pak Receives the 23 March 2016
World’s Most Prestigious Manufacturing Award.
http://www.tetrapak.com/ Global Leaders’ Initiative Award Keynote Speech
about/newsarchive/tetra-
pak-receives-the-worlds-
most-prestigious-
manufacturing-award

World Class Award

Mr. Lars Wennberg Zen-in sanka

Vice President (All members
Terta Pak Participation)

Empowered people deliver

Tetra Pak Production d.o.o. breakthrough results!
Gornji Milanovac, Serbia
5
 TPM Activity Progress
AI: Artificial Intelligence ISO/IEC
Cyber Physical System Asset Management

Administration
Data Analysis Standardization
Product
Development
Planning
Io
Material
Delivery Customer
Supplier Supply Factory

Outsourcing Company

Connected Equipment
Business Chain Producer

IoT: Internet of Things

6
 KMI/KPI/KAI(Example)
S:Safety
KMI : Key Management Indicator P:Productivity
KPI

Local Factories
KPI : Key Performance Indicator Q:Quality
C:Cost
KAI : Key Activity indicator D:Delivery
E:Environment
ＫＭＩ ①Revenue ②Profitability ③Safety ④Quality M:Moral

ＫＰＩ ＫＡＩ:Number of Kaizens and Activities

OPL: One Point lesson
Ｓ Accidents Near Accidents finding, Essential Safety Design PM-Analysis
P:Phenomena/Physical
Ｐ OEE Defect Tag, OPL, PM-Analysis, RCM M:Mechanism/Machine
/Method/Material/Man
New Product Ratio Co-development with Customers, FMEA,FTA RCM: Reliability-Centered
Maintenance
Ｑ Claim, Quality Quality of Modules, Supplier Assessment, QFD FMEA: Failure Mode
Effects and Analysis
Ｃ Cost Reduction KAIZEN, New Material Evaluation, etc. FTA：Fault Tree Analysis
QFD：Quality Function
Ｄ Lead Time “MAKIGAMI” （Process Step Reduction), VSM Deployment
VSM: Value Stream
Ｅ Save Energy, etc. Energy Conservation, Wastes Reduction Mapping

Ｍ Skill Management Seminar, Qualification, Certification

 KMI/KPI/KAI & Loss-Cost Matrix
Strategy
KMI KMI KMI
KMI
(New Product) (….)
(Revenue) (Profit)

Cost Reduction Cost Structure

Leadership Loss Cost
Target
Matrix
Loss Finding
KPI
KPI
KMI : plan
Key Management
Indicator KAI Standardization
Kaizen KAI
KPI :
do action
Key Performance
Indicator
Evaluation
KAI : check SOP
Key Activity
indicator (Standard Operating Procedure)
Management
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 KPI Performance Improvement/Year
Accidents Customer OEE Energy
Complaints

Δ%/Year Δ%/Year Δ%/Year Δ%/Year

0
-1
-2
1.7% -3
-4
9% 4.9%
12% -5
-6
-7
-8
-9
-10

-9%/Year -12%/Year ≒+2%/Year -4.9%/Year

(Minor Accidents)
Data: From 2012TPM Award winners (World-class～Consistent)
Energy: 2014 TPM Award winners

9
 TQM/TPM/TPS
・Tanpin Kanri (Tyota Production System)
(Management by single product)
TPS
・Waste/ Unevenness/ Strain
Elimination
・KANBAN
(Index Board) ・Just in Time ・Heijunka
(Process Smoothing)
・Poka-yoke ・Autonomation
・ANDON
(Failsafe)
(Signboard)
Reliability Efficiency
・KARAKURI KAIZEN
Respect
for ・OEE:
・Quality ・Policy Humanity
Management （Overall
Function ・Autonomous
Equipment
Deployment ・Statistical Maintenance
Excellence Efficiency）
Process
・Loss Zero ・Loss-cost
・QC 7 tools Control
Matrix
TQM TPM
(Total Quality Management) ・GENBARYOKU (Total Productive Maintenance)
(Wisdom of work place)
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 TPM: A Foundation for Asset Management
MAINTENANCE
TECHNOLOGY
Sept. 2014
Editor:
Bob Williamson
CMRP, CPMM,
and Member of
Institute of
Asset Management

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 Asset Management & TPM
ISO55000s Future
Line of sight Present
Target
Past Gap=Loss TPM
Zen-in sanka
Present (All members Participation)
Situation
“Productivity” is an attitude of mind. (European Productivity Agency1958)
It is the will to improve on the present situation, no
matter how good it may seem, no matter how good it
may really be.

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Top Down and Bottoms Up for Excellence

Line of sight Top

・Goal

Middle
・Target
Zen-in sanka
全員参加
(All members
Operation Participation)
・Motivation
If abnormality happens, operators are authorized to stop a line,
and find out a true cause in "Zen-in sanka" way.

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 Global Innovation with IoT
Industrial Internet

Industry 4.0

CPS:
Cyber Physical System
AI:
Artificial intelligence

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 Revolution in Manufacturing
Customer
Servitaization Real time Indicators
Development Real
KMI/KPI/KAI
CAD
Open Intelligence ⇒Real Management
Source
(Design) Simulation
Cyber Physical System Open
Source
Cyber Digital ⇒Intelligence AI：Data Analysis (Prod.)

Production
Real Spare parts
Real ⇒Digital
（Hard/Soft/Webb
AI : Abnormality
/3D printing）
detection
AI：Knowledge &
Experience

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Innovation in Maintenance Technology
Model(Deductive)

Cyber Physical System

Deep Learning
Simulation
Ex).Self-Organizing Map
Ex).LES: Large Eddy for Reinforcement Learning
Simulation
Theory Data Analysis
Ex).SVM: Support Vector Machine

Experiment
Experience

Data (Inductive)
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Introduction of Highly Precise Simulation
Duct Gas flow Analysis
IDEMITSU ENGINEERING CO.,LTD.
Confidential Copyright © 2015 by IDEMITSU ENGINEERING
CO., LTD. (IEC)
To be reproduced and used only in accordance with written
permission of IEC

Frequent breakdown

LES(Large Eddy Simulation)

改善後
After Improvement
17
Deep Learning

Preferred Networks
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Application of AI(Artificial Intelligence)1

Renesas Renesas Electronics Corporation

http://www.renesas.com
Data Acquisition Data Analysis

High Speed Machine

Low Power learning MES or SCADA
Real Time Artificial
communication Intelligence
Ethernet Add-on to Ethernet

Anomaly Predictive R-IN+AI

Detection Maintenance

ＸCompass intelligence Ltd

http://www.xcompass.com
MES(Manufacturing Execution System）

SCADA（Supervisory Control And Data Acquisition）

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Application of AI(Artificial Intelligence)2
Learning normal wave form
Normal
V
Threshold level (Conventional)
Input Wave
Monitored Voltage

Conventional
Threshold
Wave Form
can not detect
Generated by AI
Abnormality
Error Wave
Abnormal
Gap between learned Normal wave
V and abnormal wave
Early Prediction
Threshold (New) become available

Monitored Data
New Threshold enables
Abnormality Detection Equipment
X6 Higher than conventional method Breakdown

High Speed Sampling (50ms)

Manufacturing day
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 The Future of Japanese Work Force
Work force decline Replaceable by AI & Robot
(Million) in 10-20 years
Total population 60 49%
150 47%
128 107 35%
-16% 40
100
77 58
-25% 20
50
Work force 0
0
Japan UK USA
2015 2040 Nomura Research Institute &
Tohmatsu Venture Support Co., Ltd C. Frey and M. Osborne (Univ. of Oxford)

Replace Priority Monthly Cost / person(robot)

1. Heavy / Dirty / Dangerous Japan $2300
2. Multi / Speedy / Restless China $640
Robot $160 ( 24H / 5 years dep.)
( Japan center for Economic Research) ( Softbank)
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 Human skills required in IoT, I-4.0 era①
Empowered Operator

Maintain
８ Human
Autonomous Centric
Step

Condition Setting
７ Maintenance
Operator Recovering

６ Anomaly detection Assisted by

(Can invent)
AI, IoT
Big data
５ Can teach
Traditional
Operator Do with confidence
４ Simple
Can do operation
Heavy Robots
Dirty Karakuri
３ Poor Operation Dangerous -Kaizen®
operation
２
Scope
１ 22
 Certification for Skilled Operators
English version textbook has
started sale in May 2016
Jishu-Hozen-Shi

Number of Certified Skilled

Operators (Autonomous
Maintenance) exceeds
Correct Monodzukuri
cumulatively 130,000 in Japan
Monodzukuri Test (Manufacturing) knowledge
all over the world !!

Next Step ･・ Deployed

in Thailand
from 2014
Monodzukuri Test in Thailand
Analysis service 23
Karakuri Kaizen®

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 Human skills required in IoT, I-4.0 era②
Empowered Maintenance Expert
IT oriented

Design & Development

８ Designer Deep Learning
Step

oriented Simulation Cyber Physical System

７
Analysis
FMEA Risk
６ Intelligent
Needs and data
Collaboration
５ Maintenance Sensors with IT &
Prevention Design
Traditional PDM: Predictive
４
Maintenance TBM: Time Based Partially
Expert Conventional transfer to
３ BDM: Breakdown Maintenance skills Empowered
Operators
２
Scope
１ 25
 Japan’s activity on IoT , Robot
Robot Revolution Initiative
https://www.jmfrri.gr.jp/english/
Manufacturing
WG1: WG for manufacturing
business revolution
through IoT
Bridged by METI
IoT Acceleration Consortium
All area
http://www.iotac.jp/en/
Business matching, Financial
Support, Regulatory Reform
METI: Ministry of Economy, Trade and Industry
Cooperation between
Platform Industrie 4.0 Germany
and Robot Revolution Initiative Japan
(28. April 2016)
Joint Statement
http://www.meti.go.jp/press/2016/04/20160428011/20
160428011.pdf
Industrial Value chain Initiative
https://www.iv-i.org/en/index.html
Manufacturing
Efficient Value Chain migration
with open and closed strategy
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Robot welcomed Chancellor

27
 Global standard & Practice
3 Wisdoms for Success
(by Mencius) “de fact”
Industrial Internet
天 (Heaven)
“de jure” Luck brought by heaven

IoT: Internet of Things

Industry 4.0
地 (Ground)

Advantage of geography CPS: Cyber physical System

AI: Artificial Intelligence
Industrial Value chain Initiative
“de pratique” https://www.iv-i.org/en/index.html
Robot Revolution Initiative
人 (Human)
https://www.jmfrri.gr.jp/english/
TQM/TPM/TPS
Harmony of human
(6σ/TPM/Lean)
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 Why “Human view point” is important?
Negative aspects of Industry Revolutions
Industry Revolution Risk
1st Vapor, fossil fuels (Power) Global warming
2nd Electricity, Quantum Mech. (Energy) Atomic bomb
3rd Computer & Communication (IT) Hacking
4th Cyber Physical System, AI Singularity

Delay of preventive measures

may cause human extinction.
Only Human can cope with it.

“Luck brought by Heaven is less than advantages of Geography.

Advantages of Geography is less than Human harmony.” (by Mencius)

“Respect for Humanity”

is the base for sustainability.
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 Maintenance & Sustainability
Message from Mr. TPMs
I believe that TPM activity
The basic philosophy of TPM
will strongly support
must be the contribution to
strategies that effectively
the sustainability of
accomplish sustainability
companies or society.
and growth of business.
Late Mr. Tokutaro Suzuki Late Mr. Seiichi Nakajima
Humanity

Preventive Zero loss

Sustainability

Actual Scene/Thing Breakthrough

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