TOTAL PRODUCTIVE MAINTENANCE

Total Productive Maintenance

• Total
Total participation - everybody is involved
Total machine
Total life cost of ownership
Total effectiveness
• Productive
Optimal equipment conditions for Production
Optimal maintenance-process Performance
• Maintenance
Maintenance Prevention
Improved Maintainability
Preventative Maintenance
Moving from the old attitude “I operate it and you fix it!” to the new attitude “We are all responsible
for our equipment!”
Goals and Activities of TPM
 The 3 Principles of TPM...

1) Detection: Using preventive and predictive technologies to

inspect, detect and then correct small defects before they can
become costly repairs
2) Restoration: Restoring equipment to optimal conditions
3) Prevention: Preventing small defects from becoming major
problems by correcting them before they become costly
repairs
 Types of Maintenance
 Maintenance Prevention - designing or selecting equipment that will run with minimal
maintenance and is easy to service when necessary.
 Predictive Maintenance - determining the life expectancy of components in order to replace them
at the optimum time.
 Autonomous Maintenance - involving production employees in the total machine maintenance
process. Goes with 5S well.
 Preventive Maintenance - using schedules or planned maintenance to ensure the continuous,
smooth operation of equipment.
 Systematical Preventive Maintenance : tasks to be systematically performed on schedule
 Conditional Preventive Maintenance : tasks to be performed or not after scheduled checking
 Corrective/Reactive Maintenance - Fixing an existing equipment when it breaks or looses its
original performance
Breakdown Frequency VS Breakdown Lead Time

Corrective  Preventive Maintenance

Autonomous Maintenance
AUTONOMOUS MANAGEMENT
 Autonomous Management
• Definition : Direct participation of production operators in the
management of the machine through daily check, lubrication, early
detection of abnormalities, replacement of parts or small repair.

• Is the system to re-educate ourselves whilst restoring and improving our

machines :
• Developing our people and enabling them to take care of their
machines
• Influencing of the personal attitudes, value and behaviors of our
employee to continually enhance the condition in which they work
• Creating the base and the resource for performance improvement

Through AM We change our people and machines !!

 Pillar II : Autonomous Maintenance

Autonomous Management : Definition

SHARED RESPONSIBILITY OF MAINTAINING ”BASIC CONDITIONS” OF
EQUIPMENT BETWEEN PRODUCTION AND MAINTENANCE

 Daily/Time-Based Maintenance
– Cleaning
– Lubrication
– Tightening

 Daily inspection by using 5 SENSES

 Right operation, right adjustment, right setting

“I operate, You fix.” “We are AlI responsible for

Our equipment.”

“I operate, You Clean.” “We are AlI responsible for

cleanliness of Our line.”
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Why Autonomous management necessary and
which skill are required by operators?
What are the expected result of Autonomous
Management implementation?
 Available Time = 100 % OEE
1.1.Equipment
EquipmentStop
StopLoss Pallet
Loss Pallet
Jams,
Jams, Silo stops, Slide Gate,etc
Silo stops, Slide Gate, etc

Downtime
Operating Time 2.2.Set
Setup/Adjustment
up/AdjustmentLoss Sensor
Loss Sensor
Dirty
Dirty / Off, Adjust Former height,etc
/ Off, Adjust Former height, etc

3.3.Parts
PartsChange
ChangeOut
Out Leaky
Leakycylinder,
cylinder,
Change Over Loss, Wait System,
Change Over Loss, Wait System,

4.4.Start
StartUp
UpLoss Change
Loss ChangeOvers,
Overs,

Performance
Net Not ready at 4AM,12 Noon, 8PM
Not ready at 4AM,12 Noon, 8PM
Operating
Time 5.5.Minor
MinorStoppage
StoppageLoss
LossLack
Lackofof***
***
Dribbler adjustments, Bags jamming
Dribbler adjustments, Bags jamming

6.6.Speed
SpeedLoss Run
Loss RunRate,
Rate,Machine
Machine
Speed – Conveyor Belts, Dribbler,etc
Speed – Conveyor Belts, Dribbler,etc
Valued
Wasted$$’s
Quality

Operating
Time = 7.7.Defect/Rework
Defect/ReworkLoss
Loss
Bad
Badformula,
formula,
25 % OEE Wrong
Wrongingredients,
ingredients,On
Onhold,
hold,etc
etc

15
3 Key Tools for Autonomous Management

KeyConcepts
Concepts
Key 33 Key
Key Tools
Tools

••Shop
Shopfloor
floorbased
based
activities
activities  Activity
 Activity Board
Board
••Operator
Operatorconducted
conducted
••Operator
Operatorenhancing
enhancing
 Meetings
 Meetings
••Team
Teamactivity
activity
••Autonomous
Autonomous
Management
Management  One
 One Point
Point Lessons
Lessons
••TPM
TPMFoundation
Foundation
••Part
Partof
ofthe
thejob!
job!
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 Example of A.M. Activity Board
Activity & Findings Treasures
People
Team Team Mission •Display actual findings from
Step 1: Initial Cleaning Initial Cleaning such as trash,
•Team Name •Mission
•Members unnecessary items, dust and
•Objectives Definition other contamination.

Step 2: Sources of Contamination

Pictures Before After

Explain and show Focused

Line Improvement activities
for sources of contamination
Layout of Line &
Identified Important
Areas
Tag List Production Maintenance
Safety Hazard One-Point-Lessons

Contamination
Tag Movement
Hard-to-reach
Actual Tags
Main Failure

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 Autonomous Maintenance
Routine Cleaning, Inspection, & Lubrication Standard
Dept. / Line : Bldg Y Area : Bag Printer Mach. ID : Date: 4/28/2004 Tag # :
T Person
Freq
Diagram No. Item Criterion Method Tools (Min) Resp.
S D W M
Cleaning
1 Water trap Empty bowl Open valve Cloth 1 X Operator

Insert This is the maximum level for water in the bowl.

Open valve at bottom to release water, wipe up with clean cloth.

Picture

Here

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 One Point Lessons
OnePoint
PointLesson
Lessonisisaatool
tool
TPM One-Point Lesson
One No.
withthe
thefollowing
following
DL1034
Compressed Air Usage

Subject
with For Line #1 & 2 Date of
characteristics;
characteristics; Creation
November, 2003

Dept. Super- Team Created

Classification
Manager visor Leader by

One
 Onesheet
sheet Basic Im provem ent Trouble
John Jerry Paul Daniel

totoshare
 sharethe
theresults
results Knowledge Example Cases

ofautonomous
of autonomousstudy
study 1.Compressed Air

for 1 may only be used on

 for5-10
5-10minutes
minutes the Dribbler Scale
ONLY

2.Scale Area is
currently Hard-To-
Contentscan
Contents canbe beknowledge
knowledge Reach and may
andskills
and skillsof;
of; cause variable
2
Equipment
Equipment weight if not
cleaned
Safety
Safety Don’t Make A Bigger Mess !!!

Operation
OperationProcess
Process Date

Action History
Executed

Task
Task Instructor

Trainee

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 The Five S
The Five Steps of Housekeeping
1. Sort: Separate out all that is unnecessary and eliminate it.

2. Store: Put essential things in order so they can be easily accessed.

Everything has a place… and is in its place. And visual management.

3. Shine: Clean everything – tools and workplaces – removing stains,

spots, debris and eradicating sources of dirt. Bring everything to
“NEW” and better than new.

4. Standardize: Standardize the previous three steps to make the

process one that never ends and can be improved upon.

5. Sustain: Make cleaning and checking routine. 20

 WHO DOES WHAT ?
SERVICING
Mfg Maint
ACTIVITIES

REPAIR
ROBUSTNESS IMPROVEMENT X
MAINTENANCE
EFFECTIVE AND APPROPRIATE REPAIRS X

PREDICTIVE
TRENDS MEASURE AND CONTROL X
MAINTENANCE
NOT TIME BASED SERVICING X
BUILDING OF PROGRAMS X
PREVENTIVE
MAINTENANCE
TIME BASED APPLICATIONS X X
CLEANING- REFURBISHING X
GREASING-SCREWING X
ROUTINE
MAINTENANCE DAILY INSPECTION X
DAILY EQUIPMENT CARE X

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The 7 steps of Autonomous Maintenance
1. Initial Cleaning -Detect problems of lines and restore its original state.
(Initial Inspection & -Start managing the line autonomously.
“Restoration”) ( 5S, Minor Stops, Quality )
-Create & perform temporary
“Cleaning/Lubrication procedures.”

2. Source of Contamination -Solve “Sources of Contamination” and

& Hard-to-Reach areas “Hard to Reach” areas. (Cleaning, Inspection, Lubrication)

3. Standards of Cleaning -Develop tentative standards for cleaning, lubrication and

& Lubrication inspection.

-Provide training on their equipments, products and

4. General Inspection materials, inspection skills and other AM skills.

5. Autonomous Inspection Develop a routine maintenance standard by operators

6. Standardize Autonomous Standardize routine operations related to workplace

Maintenance operations management such as quality inspection of products,
life cycle of jigs, tools, set up operation and safety.

7. Autonomous Autonomous team working

Management
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 3 Phases of Autonomous Management
2. Source of
1. Initial 3. Standard of Cleaning &
Phase 1 Cleaning
contamination & Hard to
Lubrication
Clean

Phase 2 4. General Inspection 5. Autonomous Inspection

6. Standardize
7. Autonomous
Phase 3 Autonomous
Management
Maintenance Operation
 Phase 1

1. Initial Cleaning
Target of initial cleaning :
 Phase 1

What to detect during Initial Cleaning? “Categories of Abnormality”

S: Safety Items : safety area, spot, work environment
1: 5 S Related (Unnecessary) Items:
 Sort: Unnecessary items
 Store: Disorganized storage, Lack of Visual Indications
 Shine: Cleanliness/Preserve
2: Sources of Contamination:
 Leaks, Spills
3: Hard-to-Reach area
4: Minor Defect
 Contamination
 Broken Parts
 Looseness
 Abnormal Function
 Adession
5: “Basic Conditions”:
 Lubrication
 Tightening
 Cleaning & Inspection
6: Quality Related: Causes of defect

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 Phase 1

Before After

26
 Phase 1

F-Tagging
During Afterwards –
Initial Cleaning Every Day Process

27
 Phase 1

Tagging should be a continuous activity

 Phase 1

Monitoring Tags
• Initial Cleaning is not an one time event. It should be repeated monthly.
• The more restoration you continue, the less Initial Cleaning time you will
need.
250

TagIssued
Tag Issued
200

Tag
Tag
150
Number of Tags

Restored
Restored
100

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29
Phase 1
 Phase 1

Major Impact from Initial Cleaning Activity

• 10 % increase in Machine Time by cleaning and adjustment of cylinders
and air tubes of Bag Former
(13 cycle/min to 15 cycle/min)

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 Phase 1

2. Source of contamination & Hard to Clean

Target
 Phase 1

Modify Hard to Clean Parts

 Phase 1

Make Hidden Inspection Points Are Visible

 Phase 1

The best cleanliness are no need to clean !!

 Phase 1

3. Standard of Cleaning & Lubrication

Target :
Phase 1
Phase 1
Phase 1
Next >>>>> Phase 2