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1、1,A STRATEGY FOR PERFORMANCE EXCELLENCE,Total Productive Maintenance,2,Performance Excellence Series Training Module Elements,Executive Overview,Participant manual,Tools Workbook,Knowledge Breakthrough,Lecture notes,Lecture notes,3,Table of Contents Executive Overview,Session 1.0 Introduction.3 Sess
2、ion 2.0 Role in Lean Manufacturing.8 Session 3.0 Role of the Operator in TPM18 Session 4.0 Autonomous Maintenance Implementation22 Session 5.0 Equipment Performance: Measurement & Management.56,TPM,4,Total Productive Maintenance,Do these problems sound familiar? Equipment is always breaking down Ope
3、rating machines at rated speeds creates defects Setups and adjustments take too long Minor machine stoppages are eroding productivity,5,Total Productive Maintenance,A series of methods to ensure that process machines are always able to perform their functions so that production is never interrupted.
4、,6,Total Productive Maintenance,What it is: 1. Optimizes equipment efficiency 2. Implements a company wide Preventive Maintenance system 3. Involves production equipment designers, operators, and maintenance department personnel 4. Involvement from Management down to floor workers 5. Implemented thr
5、ough small, self directed team activities,7,Total Productive Maintenance,Typical success results after implementation of TPM: Breakdowns: 1/30 to 1/100 of prior level Machine defects: 1/30 to 1/40 of prior level Productivity: 30 - 100 percent increase,source: K. Shirose, TPM For Workshop Leaders, p.
6、 10,8,Performance Excellence: Expanding the Strategy through TPM,Introduction Role in Lean Manufacturing Role of the Operator in TPM Autonomous Maintenance Implementation Equipment Performance: Measurement and Management,TPM,9,The Nine types of waste,Overproduction Delays (waiting time) Transportati
7、on Process Inventories Motions Defective products Untapped resources Misused resources,9 Wastes,TPM targets reduction of these equipment oriented wastes,10,Yesterday: Problem = machine breakdown = get around the problem Solution = Work in batches “We use the time it works to mass produce”,TPM: A Lea
8、n Manufacturing Method,TPM and one-piece flow:,Today: Objective = One piece flow Quality every time Means = TPM,“We organize so it works continuously”,11,Goals of TPM,Achieve zero equipment breakdowns and zero defects through prevention. Establish prevention by Maintaining normal conditions Early de
9、tection of abnormalities Quick response,12,Present Conditions,Operators view machines as responsible for major production And limit their roles to equipment operation and inspecting for quality While maintenance workers view their function as responding to recurring breakdowns,13,Maintenance Approac
10、hes,Time Based or Planned Maintenance - Periodically scheduled maintenance actions. Predictive Maintenance - Maintenance action performed resulting from evaluation of equipment condition. Corrective Maintenance - Maintenance action performed to restore optimal equipment function. Preventive Maintena
11、nce - A combination of Time based and Predictive Maintenance and actions taken to sustain optimal equipment performance and preclude breakdowns.,14,Early Equipment Management,Optimizes equipment selection through: Equipment Life Cycle Cost Analysis : analysis of the sum of all costs (direct and indi
12、rect) associated with an item of equipment throughout its period of use. MP Design: activity which is focused on minimizing future maintenance costs and production losses of equipment at the design stage.,15,Total Productive Maintenance,Without TPM,With TPM,MED & Industrial Engineering,Maintenance,M
13、ED & Industrial Engineering,Operation,Maintenance,The operator operates, maintenance maintains, etc.,Shared responsibilities,Operation,16,Equipment Maintenance Responsibilities,MED & Industrial Engineering,Autonomous maintenance,Breakdown maintenance Planned maintenance Predictive maintenance,Mainte
14、nance prevention,17,Total Productive Maintenance,Equipment in better working condition,Decrease of breakdowns,Decrease of in-process adjustments,Optimization of operation speed,Manufacturing defects,Lead-time,Quality the first time,18,Performance Excellence: Expanding the Strategy through TPM,Introd
15、uction Role in Lean Manufacturing Role of the Operator in TPM Autonomous Maintenance Implementation Equipment Performance: Measurement and Management,TPM,19,Total Productive Maintenance,TPM, the total approach The operator is the first line caretaker Maintenance personnel are the specialized caretak
16、ers.,20,Division of Maintenance Duties between Production and Maintenance,Depending on knowledge and skills required, responsibility for equipment maintenance tasks needs to be defined: Maintenance Technician Production Operator * Equipment overhaul * Basic lubrication * Special skill tasks * Genera
17、l cleaning * Complex adjustments * Multi-point inspection * High safety risk tasks * Basic adjustments,21,Maintenance Task Allocation between Production and Maintenance,Maintenance Technicians,Production Operators,Autonomous maintenance implementation,Volume of maintenance tasks,22,Performance Excel
18、lence: Expanding the Strategy through TPM,Introduction Role in Lean Manufacturing Role of the Operator in TPM Autonomous Maintenance Implementation Equipment Performance: Measurement and Management,TPM,23,Autonomous means “independent” Autonomous maintenance refers to activities involving operators
19、in the maintenance of their own equipment.,Autonomous Maintenance,24,Autonomous Maintenance,How to make the operator more independent: Make the documentation available (manual, maintenance schedule, log book). As a team, define manufacturing/maintenance/MED productive maintenance activities. Show op
20、erator how to perform daily checks and take corrective actions. Train in basic operation, maintenance and defect detection techniques. Make daily activities visible Clearly identify items to supervise,25,Process Critical Machinery & Equipment,Map the process and identify critical equipment,Turning,D
21、rilling,Cutting,Cleaning,Stripping& Painting,Shipping,26,Adverse effects of inadequate cleaning,27,Adverse effects of inadequate cleaning:,Failure - equipment failure resulting from dirt and contamination affecting precision Product defects - contamination of products or defects arising from insuffi
22、cient cleaning Accelerated deterioration - dirt and scale buildup shortening useful equipment life Throughput loss - reduction in output due to loss of operation speed due to grime and contamination.,28,Equipment Deterioration,Normal deterioration: deterioration that occurs despite correct use and m
23、aintenance Accelerated deterioration: quicker deterioration occurring due to misuse in operation and neglect of maintenance.,29,Performance,Time,Equipment Breakdown,100%,Time and Deterioration of Performance,Need for detection of performance decline,30,Cleaning as Detection of Deterioration,Cleaning
24、 - reduces accelerated deterioration Physical contact with equipment - exposes abnormal operating conditions (i.e. vibration, noisy bearings, leaks, overheating, frayed belts, inoperative indicators, etc.) Preventive action taken - extends useful life and avoids breakdowns,31,A good clean-up allows
25、for a good inspection,Noise,Vibration,Heat,Oil,Dirt,Quickly detect,And document,Cleaning as Detection of Deterioration,32,Factors Contributing to Equipment Failure:,Equipment failures,Loose parts,Vibration,Contamination,Improper/ Inadequate Lubrication,33,Eliminate Factors Contributing to Failure:,S
26、ecure and tighten all fasteners, fittings, bolts and screws Replace any missing parts Replace any damaged, worn or wrong size parts Resolve all causes of leaks, spillage, spray and scatter,Improve accessibility in order to accomplish Cleaning Lubricating Adjusting Checking,34,Autonomous Maintenance:
27、 Tagging Abnormalities,35,Cleaning will uncover problems and undesirable conditions. Attach tag to make problem visible Resolves problems promptly and remove tags. Document plans to address those that cant be removed immediately.,Autonomous Maintenance,36,Before Tags are Removed, Ask The 5 “Whys”,Pr
28、oblem: Oil leaks from the hydraulic press 1. Why? Clogged filter 2. Why? Oil was dirty 3. Why? Metal filings got into oil 4. Why? Oil fill cap missing 5. Why? Misplaced & lost,Find the root cause,Solution! Oil filler cap attached to filler neck by a chain (Poka-Yoke),37,Equipment Performance Losses,
29、Downtime losses - time lost to equipment breakdowns, machine adjustments Efficiency losses - time lost to start up and operating cycle speeds less than ideal Defect losses - time lost to machine related quality defects and recycling.,38,Equipment Performance Losses,39,Assignable Loss versus Common L
30、oss,Defect rate,Time,Assignable loss - corrected by restoring to original conditions,Common loss - reduced by achieving optimal conditions,40,Importance of Lubrication,Some experts estimate 60% of machine breakdowns associated with moving parts are due to lack of or improper lubrication practices.,4
31、1,Lubrication Management ?,The need to lubricate equipment correctly and consistently according to usage with correct lubricants in the correct amount at specified fittings at specified time intervals ensuring coverage of contact areas,42,Visual Management of Lubricants,Green Blue Orange Red w/ Whit
32、e stripe,Oil Grease Hydraulic fluid Silicone,43,Maintenance Checklists,TPM VERIFICATION LIST At The Beginning of Each Shift Hydraulic Pressure Leaks (oil, fluids) Caps and hoses Switches Lights and lamps Body Noises/vibration At The End of Each Shift Clean Make entry in maintenance book,44,1,2,3,4,5
33、,6,7,8,9,10,Example Cleaning and Lubrication for Autonomous Maintenance,45,Basic Training in Equipment,Conduct equipment training for leaders. Leaders then train group members. Operators implement training to correct abnormalities and improve equipment performance. Implement visual controls.,46,Exam
34、ple Skills Matrix,Basic Training in Equipment,47,One Point Lesson,Purpose: To provide specific knowledge about a single topic of importance. Facilitate team training in an easy manner. Discussed on the shop floor. Types: Knowledge Improvements Solutions to problems,48,Object Name: Fasteners Subject:
35、 Identification Number: Generic types,Date prepared: 4/17/00 By: John Clark Approved: Tina Jones,One-Point Lesson Sheet,Department Date trained Name,Purpose: Identification of fastener hardware for repairs and ordering of replacements.,Maint.,Purchasing,Inventory Stores,x,One Point Lesson,Production
36、,49,TPM Deployment Effectiveness through Overlapping Teams,Plant Manager,Staff Manager,Staff Manager,Staff Manager,Dept. Manager,Dept. Manager,Dept. Manager,Supervisor,Supervisor,Supervisor,Supervisor,Operator,Operator,Operator,Operator,Operator,Maximizing Communication & Coordination,Team leaders,5
37、0,Build a Time Based Maintenance System,Determine equipment for time based maintenance,Develop maintenance criteria and intervals,Train for maintenance implementation,Execute periodic maintenance,No,Revise maintenance instructions / parts provisioning,51,Establish an Equipment Failure Database,Gathe
38、r and manage equipment failure information. Analyze for trends and patterns of recurrence. Develop and issue periodic equipment failure summary reports. Include failure summary reports as a meeting agenda item for regular review, discussion and improvement action planning.,52,Predictive Maintenance
39、as a Diagnostic Tool,53,Predictive Maintenance Deployment,Determine equipment suitable for Predictive Maintenance,Develop diagnostic methods and instructions,Diagnose equipment as defined,Execute repair,Yes,Revise maintenance instructions / parts provisioning,Document repair information,Evaluate and
40、 revise diagnostic criteria,54,Maintenance Audits,Audits are the most important factor in the successful implementation of an Autonomous Maintenance Program. They : Verify success of implementation at each step Provide improvement feedback Instill a sense of achievement and reinforce continuing effo
41、rt toward goals,55,Maintenance Audits,Example Audit Cycle,56,Performance Excellence: Expanding the Strategy through TPM,Introduction Role in Lean Manufacturing Role of the Operator in TPM Autonomous Maintenance Implementation Equipment Performance: Measurement and Management,TPM,57,Overall Equipment
42、 Effectiveness,Overall Equipment Effectiveness = Availability x Efficiency rate x Quality rate An index of the overall operating performance of equipment Points to the need to Eliminate stoppages Increase operating speed. Improve quality (less defects, rework, scrap),58,Equipment effectiveness measu
43、rement,Overall Equipment Effectiveness = Availability x Efficiency rate x Quality rate,59,Tracking Improvement Impacts On Overall Equipment Effectiveness,Improvement Activities,60,The Mission Board : A Roadmap to Action,61,Maintenance Information Management System,Maintenance Information Management
44、System Overall Equipment Effectiveness,Cost accounting Labor & material costs,Material Control Usage and inventory,Human Resources Staffing & skills requirements,Quality Assurance Product quality Productivity,Maintenance information in relation to other business process systems,62,A Key Strategy In Pursuit Of World Class Performance,Total Productive Maintenance,