WHAT I S TPM

1. WHAT IS TPM

2. W H A T I S TPM ? • A well defined methodology to optimize resources & improve performance • A culture change - “never be satisfied” • Team-work and cross functionality • Transparency and visibility • Discipline and rigour • Continuous improvement • Wireless real time data collection, data mining and data assessment

3. 16 MAJOR LOSSES • TPM is a system to organize practical, shop-floor methods to reduce losses ... EQUIPMENT 1- Failure Loss 2- Start up Loss 3- Speed Loss 4- Set up & Adjustment 5- Idling & Minor Stops 6- Defects & Rework 7- Shutdown Loss 8- Die, Jig & Tool Loss MAN POWER 10- Motion Loss 11- Measure & Adjust 12- Management Loss 13- Line Organisation 14- Lack of Automation MATERIAL 15- NTM, Consumables 16- Yield Loss ENERGY 9- Energy Loss

4. 16 MAJOR LOSSES Machine (machine time) Man (Man time) Labour efficiency Machine efficiency Operational time Working time Scheduled Downtime Man Loading Time Machine Loading time Net operational time Operational time Production man-hour loss Real working time Net operational time Downtime loss major losses obstructingequipment efficiency 5 major losses obstructingmanpower efficiency Value added time Value added time Line organisationman-hour loss Performance loss Defect in man-hour loss Defects quality loss Energy Material Material input (number, weight) Energy input Effective energy N. quality products Ideal weight of quality products

5. W H A T I S TPM ? in other words : INCREASE THE RELIABILITY OF THE PLANT

6. T E C H N I Q U E S o f TPM - Cleaning - Tagging - 5 S - Details: 1 / 30 / 300 - Teams - Loss Deployment - Audits - Communication : Boards - One Point Lessons (OPL)

7. EXIT THE “QUICK-FIX CULTURE” Sporadic loss Losses Restoration area in order to return to previous condition “Quick-fix zone” Objective Optimal conditions Chronic losses Zero defects Time Innovation area to achieve optimal conditions C U L T U R E C H A N G E

8. TPM Machine (machine time) Man (Man time) Top Management Language $ $ Middle Management Language $ AND TECHNICAL Junior Management and personnal Language TECHNICAL COMPANY LANGUAGES Source : Juran CAN SPEAK ALL COMPANY LANGUAGES

9. ......... AM PILLAR PM PILLAR FI PILLAR TPM ORGANISATION BOARD AM=AUTONOMOUS MANAGEMENT PM= PROGRESSIVE QUALITY FI=FOCUSED IMPROVEMENT OVERALL WCMCOORDINATOR Machine (machine time) Man (Man time) PLANT WCM COORDINATOR Machine (machine time) PLANT STEERING COMMITTEE STRUCTURE $ DEPARTMENTAL COMMITTEE STRUCTURE AREA COMMITTEE STRUCTURE TPM TEAM STRUCTURE

10. Cost that can be attacked Losses Cost that can not be attacked Actual Cost Cost that Adds Value LOSS DEFINITION

11. LOSSES OF UPTIME AVAILABILITY LOSSES PERFORMANCE LOSSES QUALITY LOSSES SPEED LOSSES SHORT STOPS BREAKDOWNS START UP SIZE/ BRAND CHANGE DEFECTS SCRAPS OVERUSAGE LOSSES OF UPTIME AUTONOMOUS MANAGEMENT TEAMS PROGRESSIVE QUALITY TEAMS PLANNED MAINTENANCE TEAMS FOCUSED IMPROVEMENT TEAMS These teams attack individual loses with different methodologies

12. Waste Losses: Quality Losses: Hold Losses: Performance Losses: Speed Losses: Short Stops: Availibility Losses: Breakdown Losses: Size Brand Change Startup Losses: UPTIME LOSS DEPLOYEMENT OF UPTIME (OEE) 100 % UPTIME IS AN INDICATION ON ‘’WHAT WE DO GOOD’’ THE PORTION ABOVE UPTIME THAT SUMS UP TO 100 % SHOWS THE LOSSES LOSSES NEEDS TO BE DEFINED AND DEPLOYED SYSTEMATICALLY FOR GOOD ANALYSIS