Total Productive Maintenance (TPM)

1. Total Productive Maintenance (TPM) 1 1 © Operational Excellence Consulting. All rights reserved. © Operational Excellence Consulting. All rights reserved.

2. NOTE: This is a PARTIAL PREVIEW. To download the complete presentation, please visit: https://www.oeconsulting.com.sg Learning Objectives 1. Understand the concept and philosophy of TPM 2. Learn the 8 pillars of TPM activities and step-by-step implementation approach 3. Learn the TPM tools and be able to identify and eliminate loss 4. Learn how to kick-start TPM deployment with Autonomous Maintenance, Planned Maintenance, Focused Improvement, and Education & Training activities to improve equipment effectiveness 5. Understand the roles of a TPM implementation organization and the critical success factors 2 © Operational Excellence Consulting. All rights reserved.

3. Outline 1. Overview of TPM 2. TPM Foundation: 5S & Visual Management 3. Key Tools for TPM 4. Equipment Loss Analysis & OEE 5. The Eight Pillars of TPM 6. TPM Implementation 7. JIPM TPM Excellence Award 3 © Operational Excellence Consulting. All rights reserved.

4. Overview of TPM Machine Failures Have Many Hidden Causes Failure is what we see but is only the tip of the iceberg Visible Failure Contamination Wear Loosening Minor machine defects are generally unnoticed but are the cause of almost all machine failures Less Visible Leaks Corrosion Deformation Flaws Cracks Vibration Improper Temperature Backlash 4 4 © Operational Excellence Consulting. All rights reserved.

5. Murphy’s Law “Anything that can go wrong, will go wrong.” Edward A. Murphy, Jr. © Operational Excellence Consulting. All rights reserved. 5

6. Overview of TPM An Effective TPM Program Extends the Useful Life of Equipment The Bathtub Curve Preventive Maintenance Extends the Useful Life Failure Rate Infant Mortality Failures Wear-Out Failures Useful Life Failures (Constant Failure Rate) 0 Time 6 6 © Operational Excellence Consulting. All rights reserved.

7. Overview of TPM What is TPM? Total Productive Maintenance (TPM) is a method to achieve maximum equipment effectiveness through employee involvement Management + Operators + Maintenance 7 © Operational Excellence Consulting. All rights reserved.

8. Overview of TPM What TPM Is NOT § A maintenance department program § Just a workshop or kaizen event § A way to eliminate skilled trades (maintenance staff, technicians, etc.) § Making operators and office staff into skilled tradesman 8 © Operational Excellence Consulting. All rights reserved.

9. Overview of TPM TPM Provides Basic Stability for Lean Transformation Goals: highest quality, lowest cost, shortest lead times Just-In-Time • Continuous flow • Takt time • Pull system • Flexible workforce Involvement Jidoka • Separate man & machine work •Abnormality Identification • Poka yoke • Visual Control Heijunka Standardized Work Kaizen Focus of TPM Stability Source: Adapted from Toyota Production System 9 9 © Operational Excellence Consulting. All rights reserved.

10. Overview of TPM TPM is a Paradigm Shift Operator Maintenance Operator Maintenance I maintain & I fix I use We maintain Old Attitude TPM Attitude 10 10 © Operational Excellence Consulting. All rights reserved.

11. Overview of TPM TPM Facilitates a Culture Change Culture Attitude The way we think Behavior The way we act Work Systems & Processes Waste elimination 11 11 © Operational Excellence Consulting. All rights reserved.

12. Overview of TPM Why is TPM Important? § TPM improves teamwork skills and flexibility between operators and maintenance staff § TPM improves equipment availability (uptime) § TPM saves us money 12 © Operational Excellence Consulting. All rights reserved.

13. Overview of TPM TPM Goals § Maximize equipment effectiveness § Zero breakdowns § Zero defects § Zero accidents Zero waste! 13 © Operational Excellence Consulting. All rights reserved.

14. Overview of TPM Eight Pillars (Strategies) of TPM TPM Goals: Zero Defects, Zero Breakdowns, Zero Accidents Safety, Health & Environment Autonomous Maintenance Focused Improvement Planned Maintenance Education & Training Quality Maintenance Early Management Office TPM 5S & Visual Management 14 14 © Operational Excellence Consulting. All rights reserved.

15. TPM Foundations Sort: Identifying Red-tag Targets Raw materials, procured parts, processing parts, in-process inventory, assembly parts, Semi-finished products, finished products Inventory Types of Items Machines, equipment, jigs, tools, cutting bits, gauges, Measuring instruments, dies, carts, conveyance tools, worktables, cabinets, desks, chairs, supplies Red-tag Equipment Targets Floors, walkways, operation areas, walls, ceilings, lightings, shelves, storage areas, warehouses Physical Areas Source: Adapted from 5S for Operators, Productivity Press 15 15 © Operational Excellence Consulting. All rights reserved.

16. TPM Foundations Example of Partial Cleaning/Inspection Checklist Main Response Clean Lubricate Replace Restore Mechanism Point No. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. Is there any dirt or dust at the oil inlets? Do the oil level indicators show adequate levels? Can the oil level indicators be clearly seen? Are there any cracks in the oil tank? Is the bottom of the oil tank dirty? 1. Oil Inlets 2. Tank Is the oil in the tank dirty? Is there any oil leakage from the tank or pipe joints? Are oil levels adequate? Is the correct type of oil being used? Is there any clogging in the oil pipes? 3. Oil Pipes 4. Lubrication Sites Is there any dust or dirt at lubrication sites? Are the lubrication tools dirty? Source: Adapted from 5S for Operators, Productivity Press 16 16 © Operational Excellence Consulting. All rights reserved.

17. TPM Foundations Visual Control – TPM Scorecard Defect Rate Delivery Performance Percent, % PPM 1200 1000 Better 95 800 90 600 Better 85 400 80 200 '17/9 '18/3 '18/9 '19/3 '19/9 '20/3 '20/9 '17/9 '18/3 '18/9 '19/3 '19/9 '20/3 '20/9 Accidents Staff Suggestions Accidents/Year Suggestions/Year 100 5 4 80 Better Better 3 60 2 40 1 20 0 0 2017 2018 2019 2020 2017 2018 2019 2020 17 17 © Operational Excellence Consulting. All rights reserved.

18. Key TPM Tools Fuguai Tagging Afterwards – Everyday process During initial cleaning Tag is removed only after the repair is made 18 18 © Operational Excellence Consulting. All rights reserved.

19. Key TPM Tools Monitoring Tags 250 Tags Issued 200 Number of Tags 150 Tags Restored 100 50 0 July Novomber December August September October June 19 © Operational Excellence Consulting. All rights reserved.

20. Key TPM Tools Types of One-Point Lessons 1. Basic Knowledge Lesson 2. Examples of Problems 3. Examples of Improvement • Training tool designed to fill in knowledge gaps • Based on problems that have already occurred, these lessons are designed to communicate knowledge or skills to help operators prevent similar problems from happening in the future • To ensure that successful improvement ideas are used widely, these lessons present what needs to be done to prevent or correct equipment abnormalities • To ensure team members have consistent knowledge they need for daily production and TPM activities • It describes the approaches, actions, and results of specific improvement projects • Lessons are focused on equipment subsystems, safety points, or basic operating information 20 20 © Operational Excellence Consulting. All rights reserved.

21. Key TPM Tools Example: One-Point Lesson TPM One-Point Lesson One-Point Lesson is a tool with the following characteristics: No. DL4301 Compressed Air Usage For Line #1 & 2 Subject Date of Creation November, 2010 Ø One sheet… Super- visor Team Leader Created by Dept. Manager Classification Ø To share the results of autonomous study… Tom Mark Paul David Basic Knowledge Trouble Cases Improvement Example 1. Compressed Air may only be used on the Dribbler Scale ONLY Ø For 5-10 minutes 1 2. Scale Area is currently Hard-To- Reach and may cause variable weight if not cleaned Contents can be knowledge and skills of: Ø Equipment Ø Safety Ø Operation process Ø Task 2 Don’t Make A Bigger Mess !!! Date Executed Action History Instructor Trainee 21 21 © Operational Excellence Consulting. All rights reserved.

22. Equipment Loss Analysis & OEE The Machine Loss Pyramid Example 1 Breakdown (function loss) Motor burns out 10 Minor Stoppage (function reduction) Motor overheating 30 Minor Failures (no function reduction) Vibration causes bearing deterioration Hidden Failures (no function reduction) Hundreds Loose bolts and nuts To prevent breakdowns, we must track and prevent these hundreds of minor and hidden failures. Source: Based on Herbert Heinrich, Industrial Accident Prevention, 1931 22 22 © Operational Excellence Consulting. All rights reserved.

23. Equipment Loss Analysis & OEE “World Class” OEE § “World class” OEE is a standard which is used for comparison or benchmarking For discrete manufacturing industry: OEE Factor World Class Availability 90 % Performance 95 % Quality 99 % OEE 85 % § It should be cautioned that the “world class” OEE standard may not be applicable to all types of industries 23 © Operational Excellence Consulting. All rights reserved.

24. Equipment Loss Analysis & OEE Six Big Equipment Losses Frequent Sites Six Big Losses § Conveyors § Transport § Automatic welders Breakdowns Availability § Presses § Paint processes § Molding machines Setups & Adjustments § Machine tools § Presses Reduced Speed Overall Equipment Effectiveness Performance § Transfer devices § Sensors § Automated assembly Minor Stops & Idling § Grinding § Presses § Seam welding Defects & Rework Quality § Raw material § Components § Fuel Startup & Yield Loss Source: Adapted from Japan Institute of Plant Maintenance (JIPM) 24 24 © Operational Excellence Consulting. All rights reserved.

25. Equipment Loss Analysis & OEE Equipment Losses & OEE Six Big Losses OEE Factors Equipment Breakdowns per machine (stopped longer than 10 mins) – less than once a month Availability Breakdowns Planned Production Time Operating Time Planned Production Time Setups & Adjustments Setup/adjustment time – less than 10 mins Downtime Greater than 90% Operating Time Losses Achieve ideal cycle times (design speed); increase 15% or more Performance Reduced Speed Net Operating Time Losses Speed Ideal Cycle Time x Total Pcs Operating Time Minor Stops & Idling Minor stoppages and idling per machine – under 10 mins Greater than 95% Fully Productive Time Losses Quality Quality Defects & Rework Rate (including products to be reworked) – less than 0.1% Good Pieces Total Pieces Startup & Yield Loss Startup yield – 99% or more of lot Average total operating loss 30-50% Throughput process - Greater than 99% OEE = Availability x Performance x Quality Source: Adapted from ‘TPM for Supervisors’, Productivity Press Development Team 25 25 © Operational Excellence Consulting. All rights reserved.

26. Equipment Loss Analysis & OEE Strategies for Zero Breakdowns § Restore equipment § Maintain basic equipment conditions § Adhere to standard operating procedures § Improve operator maintenance skills § Don’t stop at quick fixes § Correct design weaknesses § Study breakdowns relentlessly 26 © Operational Excellence Consulting. All rights reserved.

27. Autonomous Maintenance AM Activities Improve Equipment Efficiency & Upgrade Operator Skills Equipment- focused Equipment Maintenance Skills Detect Correction & Restoration Abnormalities Maintain Optimum Equipment Conditions Cleaning is Inspection Autonomous Maintenance TPM/Lean Culture Traditional Culture Learn Equipment Structure & Function Autonomous Management Operator’s Knowledge Visual Workplace Standards & Inspection Operator- focused 27 27 © Operational Excellence Consulting. All rights reserved.

28. Autonomous Maintenance Example: AM Activity Board Results Activity & Findings People Team Mission Team Display actual findings from Initial Cleaning such as trash, unnecessary items, dust and other contamination Step 1: Initial Cleaning • Mission • Objectives • Team Name • Members Definition Step 2: Sources of Contamination Pictures Before After Line Explain and show Focused Improvement activities for sources of contamination Layout of Line & Identified Important Areas Production Maintenance Tag List One-Point-Lessons Safety Hazard Contamination Tag Movement Hard-to-reach Actual Tags Main Failure 28 28 © Operational Excellence Consulting. All rights reserved.

29. Autonomous Maintenance Four Equipment-related Skills for Operators Detect 1 Abnormalities Correct & Restore Abnormalities 2 Set Optimum Equipment Conditions 3 Maintain Optimum Equipment Conditions 4 29 29 © Operational Excellence Consulting. All rights reserved.

30. Autonomous Maintenance Example: Establish Cleaning Standard Autonomous Maintenance Routine Cleaning, Inspection, & Lubrication Standard Area : Bag Printer Dept. / Line : Mach. ID : Date: Tag # : Bldg Y 4/28/2004 T (Min) Person Resp. Freq Diagram No. Item Criterion Method Tools S D W M Cleaning Water trap 1 Empty bowl Open valve Cloth 1 X Operator This is the maximum level for water in the bowl. Insert Open valve at bottom to release water, wipe up with clean cloth. Picture Here 30 30 © Operational Excellence Consulting. All rights reserved.

31. Autonomous Maintenance Example: AM – Who Does What? Maintenance Activities Production Maintenance X ROBUSTNESS IMPROVEMENT Breakdown Maintenance X EFFECTIVE AND APPROPRIATE REPAIRS X TRENDS MEASUREMENT AND CONTROL Predictive Maintenance X CONDITION BASED SERVICING X BUILDING OF PROGRAMS Preventive Maintenance X X TIME BASED APPLICATIONS X CLEANING - REFURBISHING X LUBRICATION & TIGHTENING Routine Maintenance X DAILY INSPECTION X DAILY EQUIPMENT CARE 31 31 © Operational Excellence Consulting. All rights reserved.

32. Planned Maintenance Planned Maintenance: Main Activities Improvement of Equipment à à MTBF Improvement of Maintenance Skills à à MTTR § Preventive Maintenance § Specialized maintenance skills § Corrective Maintenance § Equipment repair skills § Maintenance Prevention § Inspection and measurement skills § Breakdown Maintenance § Equipment diagnostic skills § Support for Autonomous Maintenance § Develop new maintenance technologies 32 © Operational Excellence Consulting. All rights reserved.

33. Planned Maintenance The Four Key TPM Pillars that are Critical for Equipment Reliability Focused Improvement Autonomous Maintenance Planned Maintenance Education & Training 33 33 © Operational Excellence Consulting. All rights reserved.

34. TPM Implementation Example of TPM Implementation Structure TPM Responsible (Plant Manager) TPM Promotion Office Focused Improvement Education & Training Autonomous Maintenance Planned Maintenance Early Equipment Management Safety, Health & Environment Office TPM Quality Maintenance 34 34 © Operational Excellence Consulting. All rights reserved.

35. TPM Implementation The JIPM TPM Implementation Model 12 Steps of TPM Implementation 1 Establishing a Company-wide TPM Policy 2 Forming a TPM Committee 3 Conducting a Preliminary Education and Training 4 Setting a TPM Plan 5 Launching Autonomous Maintenance Activities 6 Launching Planned Maintenance Activities 7 Introducing Quality Maintenance Activities 8 Introducing Focused Improvement Activities 9 Introducing Education and Training Activities 10 Establishing TPM Administration Systems 11 Developing Safety, Health and Environmental Activities 12 Implementing TPM Activity Indicators & Evaluating Their Effectiveness Source: Adapted from JIPM 35 35 © Operational Excellence Consulting. All rights reserved.

36. TPM Implementation 1. Establishing a Company-wide TPM Policy § Define and communicate the TPM policy and objectives to all employees § Obtain commitment and support from top management § Develop a plan to integrate TPM with the company's business strategy 36 © Operational Excellence Consulting. All rights reserved.

37. TPM Implementation 2. Forming a TPM committee § Form a cross-functional TPM committee to plan, coordinate, and monitor TPM activities § Assign responsibilities for TPM implementation to committee members § Develop a communication plan to ensure TPM activities are understood and supported throughout the organization 37 © Operational Excellence Consulting. All rights reserved.

38. Critical Success Factors Critical Success Factors § Leadership commitment and support § Employee involvement § Comprehensive training and education § Standardizing processes, procedures, and equipment § Continuous improvement § Data collection and analysis § Measure and improve OEE 38 © Operational Excellence Consulting. All rights reserved.

39. Overview of TPM Excellence Model JIPM TPM Award Categories Award for World-class TPM Achievement Advanced Special Award for TPM Achievement Advanced Special Award for TPM Achievement Advanced Special Award for TPM Achievement Special Award for TPM Achievement Award for Excellence in Consistent TPM Commitment Award for TPM Excellence – Category A Award for TPM Excellence – Category B Source: JIPM 39 39 © Operational Excellence Consulting. All rights reserved.

40. Operational Excellence Consulting is a management training and consulting firm that assists organizations in improving business performance and effectiveness. Based in Singapore, the firm’s mission is to create business value for organizations through innovative design and operational excellence management training and consulting solutions. For more information, please visit www.oeconsulting.com.sg 40 © Operational Excellence Consulting. All rights reserved.