The Lean Enterprise

1. The Lean Enterprise Introduction to TPM – Total Productive Maintenance Lean Foundations Continuous Improvement Training

2. Learning Objectives • Learn the basic philosophy of TPM • Explain OEE and how it contributes to a TPM project, explore OEE components; define and calculate OEE • List 6 major components of equipment loss • Review and adopt the 7 steps to Autonomous Maintenance freeleansite.com

3. TPM – The Need • Process Industry relies heavily on equipment that is integrated and runs continuously • When down, losses are costly • With lower inventories, machines need to be reliable • Machining and Assembly industries becoming more mechanized to save manpower and do difficult jobs • More machines to maintain • Need to save energy freeleansite.com

4. TPM – The Philosophy • TPM aims at using equipment to its maximum and aids in reducing Life Cycle Costs (LCC) In other words - going all out to eliminate the Losses (Waste) caused by the equipment • TPM improves work activities that deal with Equipment Set-up, Operating parameters, Maintenance, Tear down, Repairs and Breakdowns • It specifically aims at the complete elimination of the ‘six major losses’ while striving for a goal of zero unscheduled downtime freeleansite.com

5. TPM - The Six Major Losses (Waste) • Downtime Losses • (1) Equipment failures • (2) Set-up and adjustments • Speed Losses • (3) Idling and minor stoppages • (4) Reduced speed (actual operating vs. designed) • Defect Losses • (5) Defects in process • (6) Reduced yield between start of production and stable production freeleansite.com

6. OEE Formulas Loss Measure Formula Metric Availability example: Efficiency example: Ratio of Quality Products example: Load – Down Time Load Time 460 min – 60 min 460 The Theoretical Cycle Time x Processed Qty Operating Time 0.5/ unit x 400 units 400 minutes Processed Amount – Amount of Defects Processed Amount 400 – 8 400 1.Unexpected Eq. Breakdown 2. Set-up & adjustments 3. Idling and minor stoppages 4. Reduced speed 5. Defects in Process 6. Reduced Yield Overall Equip. Effectiveness: = x 100% = 87% x 100% = 50% x 100% = 98% ] = ] ] = .87 x .50 x .98 = 46.2 % freeleansite.com

7. OEE Pareto Analysis by Loss Category Overall Equipment Effectiveness Loss 1 & 2 Loss 3 & 4 Loss 5 & 6 46.2 % OEE freeleansite.com

8. TPM attacks 6 major “Losses” plus Elimination of other Wastes (Mura, Muri, Muda) • Operator Time Losses • Manpower losses due to operation time being done more slowly than standard time (Cycle Time > Standard Time) • Material Losses • Losses in yield due to ‘inherent waste’ (cut-off stock, set-up pieces, prototype, etc) • Energy losses such as electricity, gas, and water when machinery is not doing value-added work • Idling losses due to inadequate sensors and product buildup on conveyors and chutes freeleansite.com

9. Best PracticesWorld-Class Goals (A TPM “Vision”) BeforeAfter Availability 87% > 90% Performance Efficiency 50% > 95% Ratio of Quality (Yield) 98% > 99% Overall Eq. Effectiveness 42.6% > 85% freeleansite.com

10. TPM – Operational Goals (Qualitative) • Increase number of suggestions • Improve level of teamwork of shop floor • Improve cross-functional teamwork • Establish maintenance throughout the total equipment life cycle • People maintain their own equipment • Machines available for just-in-time (JIT) application • Improve machine availability • Improve working environment (6S) • Improve Corporate culture and image • Improve Business performance freeleansite.com

11. TPM – Operational Goals (Quantitative) • Cost Reductions • Actual and to be reduced • Energy savings • Maintenance • Equipment Efficiencies • Zero failures (ultimate goal) • MTBF (mean time between failures) • MTTR (mean time between repairs) • Idle Time freeleansite.com

12. TPM – Operational Goals, cont. (Quantitative) • Safety • Zero accidents • Quality • Zero failures • Zero complaints • Education • Hours of training/ number of sessions • Number of KAIZEN projects • Number of Suggestions freeleansite.com

13. TPM – Definition of ‘Total’ • Total Effectiveness • Reduction in losses of all equipment to optimize its effectiveness and improve costs • Total Maintenance • Involves the whole maintenance system inclusive of equipment manufacturer, equipment engineering, and equipment user to improve maintainability • Total Participation • Everyone has a role to make TPM work • Management to set policy • Middle management, staff to support and lead • Maintenance to maintain and train • Operators to take on new maintenance challenges freeleansite.com

14. TPM – Role of Maintenance Function • Provides technical support for autonomous maintenance done by operators • Restores deteriorated equipment through checks, inspections, and overhauls • Identifies Design weaknesses and improves the equipment to error-free function (via poka-yoke) • Improves technical maintenance skills for checks, inspections, and overhauls freeleansite.com

15. TPM – Role of Operator Function • Maintains basic condition (cleaning and lubrication) • Maintains proper condition and standards for equipment usage • Partially restores deterioration • Basic skill levels in: • Changeover and set-up • Reduction of minor stoppages and adjustments freeleansite.com

16. TPM – Autonomous Maintenance Definition: • Operations maintains its own equipment • Utilize 7-step plan* (*Source: Japan Institute of Plant Maintenance) freeleansite.com

17. 7 Steps to Autonomous Maintenance Step 1 – Initial clean-up (External) • “Kick-off” program • Closely aligned with 6S (5S + 1) • Management and Staff show commitment • Clean, Sand and Paint • Identify sources of defects: • Gauge hidden • Limit switch buried in debris • Crack in Housing freeleansite.com

18. 7 Steps to Autonomous Maintenance Step 2 – Stop sources of defects (External) • Ask ‘why ?’ five times • Replace parts with cracks • Replace worn seals • Teach Operators how to modify equipment • Conduct Set-up Workshops; Practice Set-ups • Modify Equipment for easier checking and to eliminate sources for debris and contamination • Guards • Chip removal • Acrylic covers to see V - belts and moving parts freeleansite.com

19. 7 Steps to Autonomous Maintenance Step 3 – Standards Formulation • Standards for clean-up and checking • What equipment should be cleaned and checked? • What points should be checked? • Who should check? • What check sheet should be used? • How to react to changes. • Standards are to capture what has been learned in steps 1 and 2 freeleansite.com

20. 7 Steps to Autonomous Maintenance Step 4 – Overall Checkup (Internal) • Leaders (1st line Supervisors) trained • Hydraulics • Air Pressure • Electrical/ Electronics • Lubrication • Mechanical • One point lessons developed (Visual Management) • Team up Engineers, Maintenance, and Operators • Tear down equipment • Analyze defects • Present findings freeleansite.com

21. 7 Steps to Autonomous Maintenance Step 5 – Autonomous Checkup • Develop Standards for routine internal checkup • Hydraulics • Air Pressure • Electrical/ Electronics • Lubrication • Mechanical • Operator executes routine checks freeleansite.com

22. 7 Steps to Autonomous Maintenance Step 6 – Orderliness and Tidiness • Improve on Supplier Activity • Spare parts supply partners • Spare parts stores • Spare parts inventory • Improve on Tool Activity • Tool Crib orderliness • Tools frequently used at work station (refer to Visual Management/Visual Control) freeleansite.com

23. 7 Steps to Autonomous Maintenance Step 7 – “All out” Autonomous Management • Process never ends • Metrics • Audits • Each process post Result* (actual) against Goal (target) • Zero lost time accidents • Zero Defects • Zero Breakdowns • Zero set-up time or at least < 10 minutes • Practice Quick Changeovers/ SMED (see separate module) * Utilize Accountability Meetings (see separate module) freeleansite.com

24. TPM – Kaizen and Reliability Maintenance KAIZEN (see separate module) • SWAT Team approach to major problems (Focus improvement effort around 6 big Losses) • Reduction in Changeover/ Set-up time RELIABILITY • Driven by Pareto Analysis to prioritize • Data based • Reduction in MTTR • Increase in MTBF freeleansite.com

25. Reliability Maintenance • Meantime to Failure (Goal is to maximize) • Machine Breakdown • Tool Breakdown • Part Failure • Meantime to Repair (Goal is to minimize) • Diagnose problem • Correct problem • Set up Machine to make good parts • Spare parts control • Analyze using Statistical Tools • Reliability Measures • Problem Solving Tools • Vibration Analysis Tools freeleansite.com

26. TPM - Reliability Kaizen Examples 1) Tool cutting Tip (Nissan Motors) Life Cycle = 45 pieces KAIZEN #1 – Vibrational analysis to optimize rotational speed. Life cycle = 132 pieces. KAIZEN #2 – Analysis of wear pattern to optimize tool geometry. Life cycle = 305 pieces. 2) Tool cutting (Toyota Motors) Tool expensive and takes long time to set up KAIZEN #1 – Reduced set-up time from 15 minutes to less than 10 seconds. KAIZEN #2 – Studied correlation between life of tool and number of cuts between sharpening – increase life of tool five-fold. freeleansite.com

27. Planned Maintenance Best Practices • Maintenance department primarily responsible • Re-adjustment of Machines to bring back to original state • Feedback information to Maintenance Prevention Group • Collection of Reliability Data • MTBF • MTTR • Finding and coping with chronic defects • Machine accuracy control (calibration) • Schedule boards (Visual Management) • Control of • Spare Parts • Lubrication • Vibrational Analysis freeleansite.com

28. Maintenance Prevention Best Practices • New equipment design integrated w/ New Product Introduction (NPI) efforts • Input from Reliability Maintenance • Input from Preventative Maintenance • Input from KAIZEN activities • Life Cycle Costing • Design reviews (Operators, Supervisors, Engineers) • Assembly at Supplier • Final Inspection at Supplier • Maintenance and Operations Manual preparation • Safety Issues visible, aware and worked • Preventative Maintenance Schedule posted, adhered to freeleansite.com

29. TPM – Summary • Total Productive Maintenance is about: • improved equipment performance • increased equipment availability • increased equipment FPY (first pass yield) or also called FTT (first time through) • reduced emergency downtime • increased return on investment • increased employee skill levels • increased employee empowerment freeleansite.com

30. TPM – Breakout Activity With a small group, With regard to Maintenance - Decide at least 3 new improvements to put into place in your area. Decide at least 3 new measures/ metrics to adopt to sustain your Maintenance activities. Present your plan to Supervision. freeleansite.com

31. The Lean Enterprise Introduction to TPM – Total Productive Maintenance Lean Foundations Continuous Improvement Training