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T otal P roductive M aintenance TPM

T otal P roductive M aintenance TPM. Overview Dave Hoyte, CEO JL French Corporation. TPM as a Lean Initiative. Competitive costs require Spending control Defect control Downtime reduction TPM = Total Productive Maintenance Proactive (with all employees involved) Preventive

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T otal P roductive M aintenance TPM

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  1. Total Productive MaintenanceTPM Overview Dave Hoyte, CEO JL French Corporation

  2. TPM as a Lean Initiative • Competitive costs require • Spending control • Defect control • Downtime reduction • TPM = Total Productive Maintenance • Proactive (with all employees involved) • Preventive • Predictive • Planned

  3. Why Change? • ACTIONS: • Reduce defectives / scrap • Reduction of lost production time • Lowest possible cost by reducing waste

  4. Lean System Peak Performance Pull system / flow production Rapid Changeover / Customer-driven lot size Continuous Waste Reduction Lean Measures 5S Visual Factory Standardized Work T P M Variation reduction / Six Sigma In-Station Process Control Leadership by Example & Commitment Employee Involvement & Mutual Respect

  5. 7 Wastes • Transportation • Excess production • Added processes • Motion • Waiting • Inventory • Non-conformance (defectives)

  6. Causes of Waste • Excess Manning • Poor layout and material presentation • Rework and extra processes • Inconsistent / inefficient work methods • Excess Downtime • Tooling condition • Unreliable equipment • Long changeovers • Incapable process • Defectives - Rework or Replace • Incapable processes or process not compatible with customer expectations or design spec (design for mfg) • Tooling condition • Operator methods and errors

  7. Causes of Waste • Excess Manning • Poor layout and material presentation • Rework and extra processes • Inconsistent / inefficient work methods • Excess Downtime • Tooling condition • Unreliable equipment • Long changeovers • Incapable process • Defectives - Rework or Replace • Incapable processes or process not compatible with customer expectations or design spec (design for mfg) • Tooling condition • Operator methods and errors

  8. Effective TPM Eliminates 5 Losses • Equipment breakdowns • Defects, scrap, and rework • Safety Issues • Mini stoppages • Reduced speed

  9. What is TPM?? TPM is a Lean tool to optimize the effectiveness of manufacturing equipment and tooling. • Starts with 5S / Visual Factory • Builds a comprehensive Downtime Database by cause, frequency, and duration • Predicts and prevents downtime by PM system • Expands role of Operator as first point of early warning and prevention • Develops Professional Maintenance skills

  10. Operator Autonomous Maintenance Aut. Mgt. Standardization Autonomous Inspection General Inspection Seven Steps of TPM 7 6 5 4 3 2 1 7 6 5 4 3 Initial Standards Countermeasures for Contamination 2 Initial Clean-up 1

  11. TPM is Planned, Predictive, & Preventive • Starts with 5S / Visual Factory • Builds a comprehensive downtime data base by cause, frequency, and duration • Predicts and prevents downtime by PM system • Expands role of Operator as first point of early warning and prevention • Professional Maintenance

  12. 5S Workplace A safe, clean, orderly workplace is fundamental to quality, efficiency, and teams • Sort(organize) • Shine(clean) • Set in order (make orderly and neat) • Standardize(visual place for everything) • Sustain(maintain the system)

  13. TPM starts with 5S • You can’t see problems clearly when the workplace is in disarray • Cleaning and organizing the workplace helps the team to uncover problems • Making problems visible is the first step of improvement • Clean machines and workplace create pride & Safety

  14. Downtime Visual Controls • Visual or audio alerts • Abnormality obvious at a glance (e.g. stoppage, reject, control fault) • Alerting Maint and team leaders • Provide real time “scoreboard” for employees • Machine down light visible from aisle • Production status board (e.g. actual counts vs. goal) • Scrap counts and downtime minutes • Located in clear view in shop (not in control room) • Simple, self regulating, & employee managed

  15. TPM is Planned, Predictive, & Preventive • Starts with 5S / Visual Factory • Builds a comprehensive downtime data base by cause, frequency, and duration • Predicts and prevents downtime by PM system • Expands role of Operator as first point of early warning and prevention • Professional Maintenance

  16. Downtime Database • Categorize at a minimum by Equip, Tooling, C/O, Other • Segmented bar graph for E-T-O lost time • Subcategories for Equip (e.g.) • Hydraulic / pneumatic • Mechanical / lubrication • Electrical / controls • Shot-end components • Subcategories for Tooling (e.g.) • Slides • Cores • Inserts • Ejector pins • Subcategories for Other (e.g.) • Operator error • Materials

  17. Minimum Downtime Tracking Other Tools Equip

  18. TPM is Planned, Predictive, & Preventive • Starts with 5S / Visual Factory • Builds a comprehensive downtime data base by cause, frequency, and duration • Predicts and prevents downtime by PM system • Expands role of Operator as first point of early warning and prevention • Professional Maintenance

  19. Predictive Maintenance Tools • Rate/hr vs. target or historical normal output (B/W) • Database • MP2 / maintenance history • statistical probability (frequency & duration) • Physical prediction of impending failure • Sound (bearing) • Temperature (cooling water) • Flash (core pins) • Shot monitoring system • SPC on part geometry • Hydraulic pressure (ejector pins) • Spindle loads (amps) • Fluids / Lubrication analysis (milipore) • Vibration Signature Analysis

  20. Preventive Maintenance System • History of downtime by major machine & tool • Downtime measurement & tracking • Mean Time Between Failures • Average downtime • Pareto of causes at component level (eg L/S or temp sensor) • Cost to maintain • Develop PM cards based on frequency of failure and magnitude of average lost time (start small & grow) • Limit & prox switches • Shot tip / sleeve • Critical frame and cylinder mounting bolts • Expendable tools • Valves, hoses, packing, seals • PM’s have instruction, schedule/frequency & sign-off • PM’s / repairs done in window of opportunity when machine is down • Cycle count or date based execution of PM’s (eg cutter change) • PM status visual (work completed / not completed)

  21. TPM is Planned, Predictive, & Preventive • Starts with 5S / Visual Factory • Builds a comprehensive downtime data base by cause, frequency, and duration • Predicts and prevents downtime by PM system • Expands role of Operator as first point of early warning and prevention • One point lessons for operator awareness • Creates OMP (Operator - Maintenance Partnership) • Operator performs checks, problem solving, and improvements • Professional Maintenance

  22. Production Operators • Clean & Check • Observe • Categorize Active Planned Maintenance Process • Production Planning & Control • Schedule P.M. • Quality Engineers • Standards & Calibrations • Manufacturing Engineers • Equipment Planning • Equipment Studies TPM

  23. TPM OMP - Operator Maintenance Partnership • Operator training in TPM • Operator basic equip inspection & tooling checks • Operator basic cleaning • Operator lubrication check • One point lessons (capture knowledge) • TPM Board & TPM Tags (proactive operator involvement)

  24. TPM Tag System • Problem communication tool to and from maintenance, tool room, and production • Identify abnormal machine conditions • Record problem discovered by operator • Record problem found during scheduled PM • Status tracking system of requested repairs • TPM visual management tool (hang tags) • Repair history for future problem solving • TPM Tag used for recording problem & fix • Blue Tag-Operator or Maint responsible to repair • Red Tag- Safety-related request (priority)

  25. Tag Process

  26. TPM is Proactive, Predictive, Preventive & Planned • Starts with 5S / Visual Factory • Builds a comprehensive downtime data base by cause, frequency, and duration • Predicts and prevents downtime by PM system • Expands role of Operator as first point of early warning and prevention • Professional Maintenance

  27. Professional Maintenance • Equip Safety • Skill building • Cross-training • Area Maintenance • WC MRO stores • Maint Mgmt System • Down alarms • Radios • Planned PM

  28. Operator Autonomous Maintenance T P M OIL Aut. Mgt. Standardization Autonomous Inspection General Inspection 7 Steps 7 6 5 4 3 2 1 7 6 5 4 3 Prepare Temporary Standards Countermeasures for Contamination 2 Initial Clean-up 1

  29. TPM Initial Focus TPM I Step 1 Step 2 Step 3 TPM II Step 4 Step 5 Step 6 Step 7 5S prerequisite for TPM I

  30. STEP 3: Prepare Temporary Standards This step is to enhance the equipment reliability & maintainability. • Temporary Check Sheet For Clean-Up, Lubrication, Start-up, and Shut-down: • What items need to be done • Who will perform the check • How often to check • Where the location is to be checked • What to use for the inspection or cleaning • Target time to complete the task

  31. Peak Performance Continuous Waste Reduction 5S Visual Factory Standardized Work T P M TPM Summary • TPM = Total Productive Maintenance • Proactive (all employees involved) • Preventive • Predictive • Planned • TPM is an integral part of JLF Total Quality production System

  32. TPM is a Lean tool for Quality and Productivity

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