TPM - Total Productive Manufacturing

Welcome to TPM
Welcome To
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TPM Awareness Information 1
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. 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.
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WHAT IS T.P.M. ??
Definition of T.P.M :
T.P.M. IS: A PRODUCTIVE MANUFACTURING 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, Promoting the Participation for All
Employees
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T.P.M. = Medical Science of Equipment
PRODUCTION Foton AUTOMATION B-820
VIDEO-AUTO DIE-BONDER MODEL 8030A
POWER
HEATER
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The Main objective of TPM is :
Zero Interruptions
Zero Defects
Zero Accidents
Throughout total employees participation from Top Management to Operators,

based in the following activities:
Autonomous Maintenance
• Planned Maintenance
• Individual Improvement
• Quality Maintenance
• Early Equipment Management
• Education/Training (People Development)
• Safety
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PILLARS OF TPM
I P
A M M M S E
I M E M
U A A A T A A
N P O A
T I I P I R F R
Q D R P N
O N N L N AI E L
U I O L A
N T T A T NI T Y
A V V E G
O E E N E N Y
L I E E
M N I N N N G E M
D M D
O A T A E A Q E
U E E
U N N D N E U
Y A N V N
S C C C H I
L T E T
E E E S P
L
O
P
5S´s
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T.P.M.
Total Productive Manufacturing
People , Equipment and Product

Improvement by Working Together.
EXCELLENCE
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PLANT
OVERVIEW
PLANT
OVERVIEW
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TPM
Self Assessment
PLANT
OVERVIEW
TPM
Self Assessment
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TPM Self Assessment
Background
Background:
Background:
1991 First attempt to implement TPM.

 TPM consultant provides training to selected Managers,
Supervisors and Engineers.
 One coordinator with experience in Process and Maintenance is assigned to
lead TPM.
 Literature and materials, prepared and distributed.
 Lack of support and involvement results in failing the

implementation.
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TPM Self Assessment
Continuing
1996
1996
 One Staff Mgr. is assigned to lead the TPM Implementation

plant wide.
 A core team is formed on 2Q/96 with key people from 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 S´s
implementation.
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Asia
Benchmarking
PLANT
OVERVIEW
TPM
Self Assessment
Asia
Benchmarking
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TPM
TPM Benchmarking
Benchmarking
Asia
Asia Facilities
Facilities
1996
1996
Facility 1 April
Facility 2 May
Facility 3 June
Committee: 4 Chosen Folks
Objective: Learn from Asia success experiences in TPM

implementation and come up with directions for
Plant implementation.
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Benchmarking
Benchmarking Conclusions
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 line per area.

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TPM Awareness Information
 Budget assigned for consulting and external training.
14
TPM
PLANT
OVERVIEW Implementation
TPM
Self Assessment
Asia
Benchmarking
TPM
Implementation
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IMPLEMENTATION/CONSULTANT
* Q3 1996, Consultant X is selected to be Consultant.

* Training of Managers, Team leaders and Team members
* Master Plan Defined
* TPM. implementation initiated according to Consultant X recommendations
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T.P.M. POLICY
# 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

SHOP 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 PROGRAM.
# ALL AREAS MUST FOLLOW T.P.M. ESTABLISHED GUIDE LINES.
# DEPARTMENT HEAD IS RESPONSIBLE TO ACCOMPLISH AND SUPPORT

T.P.M. GOALS.
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T.P.M.
T.P.M. PLANT
PLANT WIDE
WIDE STRUCTURE
STRUCTURE
TPM
T.P.M. Office Responsible
Plant Manager
Autonomous Planned Individual

5 ´s Maintenance Maintenance Improvement
Quality Early Training People

Maintenance Equipment Safety Development
Management
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PROMOTION STRUCTURE
(OVERLAPPING SMALL GROUPS)
PLANT
MANAGER
STAFF MANAGERS
OPERATIONS
TPM PILLARS
& PROMOTION DEPARTMENT
OFFICE MANAGERS
TPM DEPARTMENT
PROMOTERS SUPERVISORS
TPM TEAM
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VISION STATEMENT:
TPM
PLANT WIDE
IMPLEMENTATION
Q1 2000
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T.P.M. IMPLEMENTATION ACTIVITIES
MANAGER TEAMS
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PREPARATION / PLANNING STAGE
# DEFINE PILOT LINES
# AMOUNT OF MACHINES INCLUDED PER LINE
# DEFINE CORE TEAM MEMBERS OF EACH LINE
# SELECT TEAM MEMBERS PER MACHINE
# START ACTIVITIES IN PILOT MACHINES (bottle neck.)
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Line and Machine Selection
PRODUCTION Foton AUTOMATION
B-820
VIDEO-AUTO DIE-BONDER MODEL 8030A
Machine 1 Machine 2
N-661
POWER
HEATER
Machine 3 Machine 4
B-609
V-701
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TPM Implementation Plan
1996 1997 1998 1999 2000
ACTIVITIES Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2
DEFINE STRATEGIES
PREPARATION MASTER PLAN
STAGE
ORGANIZATION T
INTRODUCTION TRAINING
PUBLICITY
1 P 2 3
M
I S MODEL MACHINES
T Machine 1 AUTONOMOUS MAINTENANCE
M
A Machine 2 &
P K
R Machine 3 REDUCE 6 BIG LOSSES
L I EXTEND SIMILAR MACHINES
E T Machine 4
C
M EXTEND K 30%
E IMPLEMENTATION to
N SIMILAR O 50%
T T PRODUCTION LINES
A
F
A
T R F
COMPLETE
I G
IMPLEMENTATION 100%
O E
DEFINED AREAS
N T
TPM 90 Days Explosion Plan
October November December
ww40 ww41 ww42 ww43 ww44 ww45 ww46 ww47 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
6 big losses Step 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
6 big losses Start
6 Extension teams step 1-2 2 mc 4 mc
2 Extension teams Start step 1 Start
Machine 4
6 big losses 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 Audit
Consultant visit
TPM Meeting
Local BOOT CAMP
TPM MCOE MEETING, JAPAN
Pillars meeting
T.P.M. TRANSITION CURVE
POLICIES DEVELOPMENT T.P.M. PROMOTION DELEGATION
T.P.M. PROMOTION OFFICE START INCLUDE T.P.M. IN PERFORMANCE C
MANAGEMENT MACHINES MANAGEMENT PLAN. O
FOCUS IN FEW EQUIPMENT INCLUDE T.P.M. IN JOB M
FOCUS TRAINING DESCRIPTION. M
D I
SUCCESS STORIES ACCELERATED
E T
N 5 S´s DEPLOYMENT. M
I E
A N
L CONSULTANT CONSULTANT T
IN OUT
KICK OFF
R E
E X
S P GOALS SETTING FOR
I L ALL ORGANIZATION.
S O
T R LOOK FOR ADDITIONAL WAYS
A
DEVELOP DATA COLLECTION SYSTEM A TO DEPLOY T.P.M.
N T
ATTENTION TO FOCUS TEAMS C I FINISH CONFLICT WITH THE CULTURE
TRAINING DEPLOYMENT E O ORGANIZATION ALIGNMENT
N
IMPLEMENTATION PLAN REWARD SYSTEM
RESOURCE IMPLEMENTATION CONTROL CHAOS
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KEY GOALS
1.- TOTAL EQUIPMENT EFFECTIVENESS % 85

A) Equipment Breakdown HOURS/MONTH 1/10
B) M.T.B.A. MINUTES 1x10x
C) M.T.B.F. HOURS 1x2x
2.- REJECT CAUSED BY LINE EQUIPMENT 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
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AUTONOMOUS MAINTENANCE.
MANUFACTURING SPECIALIST
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AUTONOMOUS MAINTENANCE IS:
Maintenance performed by equipment operators.
THE FIRST 3 STEPS OF

AUTONOMOUS MAINTENANCE.
STEP # 1 INITIAL CLEANING.
STEP # 2 COUNTERMEASURES FOR THE CAUSES

OF FORCED DETERIORATION AND IMPROVING
HARD-TO-ACCESS AREAS.
STEP # 3 MAKING A TENTATIVE CLEANING/

LUBRICATION STANDARD.
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AUTONOMOUS
MAINTENANCE
Formats:
Daily Cleaning & 6
4 Initial Inspection
Hot Spots, CAP-DO
5W´s Develop One
Major Problems Point lesson
Selection
Step # 1 Standardization 7
Cleaning /
3 Put F Tags Initial Cleaning Lubrication
Training in
Initial Cleaning One Point Lesson
(Inspection)
8
2 Photos Before
Photos After
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AUTONOMOUS
MAINTENANCE
Failures Analysis
4 Why´s Analysis
6
Put “F” Tags Actions in
Sources of
Contamination &
Hard access areas
Step # 2
Find & List Sources of Modify Covers For
Areas of Hard Easy Visualization
3 Access Contamination & & Quick 7
Hard Access Areas Disassemble
Find & List

Sources of
Contamination Remove “F” Tags
2 Initial Inspection
Final Inspection 8
(Audit)
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AUTONOMOUS
MAINTENANCE
4 Improve time of
execution 6
Verify Detail
actual time activities
Vs estimated
3
Put “F” Tags Step # 3
(Establish time Remove
& frequency)
3 Tentative 7
Standards “F” Tags
Cleaning / Lubrication Apply activities to

implementation similar machines
2
Develop tentative
2 standards 8
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TPM
TPMTeams
TeamsStatus
Status
October
October1997
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
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Expansion Plan
PLANT
OVERVIEW
TPM
Self Assessment
Asia
Benchmarking
TPM
Implementation
Expansion Plan
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T.P.M. DEPLOYMENT
L
I
N
E
F
L
O
W 1
CURRENT EQUIPMENT IN T.P.M.
9
9
SAME KIND OF EQUIPMENT 1997
8
1999/2000 EXPANSION
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PROJECTED PROGRESS IN TEAMS Q-1’ 98
Line A.M. STEP # 1 A.M. STEP # 2 A.M. STEP # 3
Wafer Process
Line 1 11 16 03
Line 2 03 11 01
Line 3 03 08 01
Line 4 04 01 01
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T.P.M. FOLLOW-UP
TEAMS TEAMS TEAMS Consultant X MANAGERS

PRESENTATION AUDITS MEETING VISITS PRESENTATION
6 TEAMS 6 TEAMS WEEKLY TWO DAY MONTHLY

PER PER EVERY MEETING
MONTH TWO
MONTH
MONTHS
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PLANT
Pilot Team
OVERVIEW
TPM
Self Assessment
Asia
Benchmarking
TPM
Case Study
Implementation
Expansion Plan
Pilot Team
Case Study
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PILOT MACHINE
N-62361
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Defectives
30
25
25 23
22
23
21
20 20
20 18
17
19
15
10 7
8
9
8
7
6 6 6 6 6
5 5 5
5 3
4
3 3
2
4 4
0
N-662361 N-61162 N-634766
JAN 96 FEB MAR APR MAY
JUN JUL AUG SEP OCT 96
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DOWN TIME
25%
23% 23%
20% 20% 20%
18% 18% 18%
17%
15% 15%
12%
N-662361 10%
% T. C.
5%
0%
FEB MAR ABR MAY JUN JUL AGO SEP

ENE./96 OCT./96
25%
20%
15%
N-663242 10%
% T. C.
12%
11%
10%
11%
8%
9%
7%
6%
8%
10%
5%
0%

ENE./96 OCT./96
25,00%
20,00%
15,00%
N-649666
10,00% 9%
% T. C. 8% 8%
7,50% 7%
6%
5,00% 4%
5% 5%
3%
0,00%

ENE./96 OCT./96
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CLEANING IS INSPECTION....
5’S
AUTONOMOUS
MAINTENANCE
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INSPECTION IS DETECTION.
CRASH
Broken Part
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PRESSURE
CORRECT
INCORRECT
TO MUCH
PRESSURE
ALIGNMENT
CORRECT
INCORRECT
GAUGE NO
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CORRECT
CENTERING
INCORRECT
Dummy Part
CORRECT
SYMMETRY INCORRECT
BENT
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CONTACT
INCORRECT
CORRECT
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TO STANDARDIZE AND
PREVENT RECURRENCE
One Point Lesson
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MACHINE
PERFORMANCE
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Defectives
25 23
20 18
15 “ZERO”
Defectives
10
10
6
5 3
2
1
0 0 0 0 0
0
Feb Mar Abr May Jun Jul Ago Sep

Oct-96
Sep-96 Jan-97
Dec-96
P.C. BOARD
DOWN TIME DAMAGED
25%
20% 20%
18%
15% 15%
12%
10%
% D.T.
9%
8%
7%
6%
5% 5%
4%
3% 3%
0%
Feb Mar Apr May Jun Jul Aug Sep

Oct-96 Nov-96Dec-96 Jan-97
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WHAT IS NEXT?
6 Big
LINK
Losses
4
4
Autonomous Planned
Maintenance 3 Maintenance
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TPM - Total Productive Manufacturing

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TPM - Total Productive Manufacturing

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Welcome to TPM

T.P.M. Includes the Following Benefits:

PRODUCTION Foton AUTOMATION B-820

VIDEO-AUTO DIE-BONDER MODEL 8030A

Throughout total employees participation from Top Management to Operators,

People , Equipment and Product

1991 First attempt to implement TPM.

 Lack of support and involvement results in failing the

 One Staff Mgr. is assigned to lead the TPM Implementation

Committee: 4 Chosen Folks

Objective: Learn from Asia success experiences in TPM

 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 line per area.

* Q3 1996, Consultant X is selected to be Consultant.

# MAXIMIZE OVERALL EQUIPMENT EFFECTIVENESS

# TOTAL EMPLOYEE INVOLVEMENT.

# CULTIVATE EQUIPMENT & PROCESS RELATED EXPERTISE THROUGHOUT

# ESTABLISH A RELIABILITY AND MAINTAINABILITY SYSTEM TO MAXIMIZE

# ALL EMPLOYEES MUST PARTICIPATE IN T.P.M TRAINING PROGRAM.

# ALL AREAS MUST FOLLOW T.P.M. ESTABLISHED GUIDE LINES.

# DEPARTMENT HEAD IS RESPONSIBLE TO ACCOMPLISH AND SUPPORT

Autonomous Planned Individual

Quality Early Training People

# DEFINE PILOT LINES

# AMOUNT OF MACHINES INCLUDED PER LINE

# DEFINE CORE TEAM MEMBERS OF EACH LINE

# SELECT TEAM MEMBERS PER MACHINE

# START ACTIVITIES IN PILOT MACHINES (bottle neck.)

PRODUCTION Foton AUTOMATION

VIDEO-AUTO DIE-BONDER MODEL 8030A

1.- TOTAL EQUIPMENT EFFECTIVENESS % 85

2.- REJECT CAUSED BY LINE EQUIPMENT 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

THE FIRST 3 STEPS OF

STEP # 1 INITIAL CLEANING.

STEP # 2 COUNTERMEASURES FOR THE CAUSES

STEP # 3 MAKING A TENTATIVE CLEANING/

Find & List

Cleaning / Lubrication Apply activities to

•Number of Hot Spots detected: 284

Line A.M. STEP # 1 A.M. STEP # 2 A.M. STEP # 3

TEAMS TEAMS TEAMS Consultant X MANAGERS

6 TEAMS 6 TEAMS WEEKLY TWO DAY MONTHLY

FEB MAR ABR MAY JUN JUL AGO SEP

FEB MAR ABR MAY JUN JUL AGO SEP

FEB MAR ABR MAY JUN JUL AGO SEP

One Point Lesson

Feb Mar Abr May Jun Jul Ago Sep

Feb Mar Apr May Jun Jul Aug Sep

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