Introduction to Lean Manufacturing – T otal P roductive M aintenance

1. Lorraine Fraser, P.Eng., M.Eng., MBA, CQE, CQA, CQM/OE, CSSBB Introduction to Lean Manufacturing – Total Productive Maintenance ASQ Toronto Section – November 11, 2015

2. Agenda • Introduction To TPM • Benefits of TPM • What does TPM look like? • How to implement TPM • How to Sustain TPM • Summary • Questions TPM

3. Lean Manufacturing The 7 Wastes TPM

4. Introduction to TPM What is TPM? • TPM stands for Total Productive Maintenance. • TPM Development was first published in Japan in 1982. Since then new concepts and refinements have been added to the basic program. • TPM first took root in the automotive industry. More recently it has been introduced in consumer goods, electronics, plastics and many others. • Administrative and support departments such as product development and sales also use TPM. • Production output and rate, quality, safety, and the environment depend almost entirely on the state of equipment. • TPM is a method for continuously improving the effectiveness of production equipment and processes. TPM

5. World Class Operating Excellence is Achieved using optimized work standards with group activities of associates who demonstrate ownership Safety Quality Cost Productivity People 5S & Teams Introduction to TPM Focused Improvement Environment, Health & Safety Early Equipment Management Quality Management Training & Development Autonomous Maintenance Planned Maintenance Office Logistics TPM

6. Benefits of TPM

7. Benefits of TPM Why implement TPM? • Guarantees Significant Tangible Results - Results achieved include – reduction in equipment breakdowns, lower quality defects and claims, higher productivity, shrinking inventory, lower number of accidents. • P… net productivity up by 2x • Q…process defect rate down 90% • C…production costs down 30% • D…production and work in process inventories halved • S…accidents 0 • M…improvement suggestions up by 10x • Transforms the Plant Environment – a rusty plant can be reborn as a pleasant, saffe working environment. • Transforms the Employees - As concrete results are achieved, workers become motivated. Associates begin to think of TPM as part of their job. TPM

8. TPM Visibly Transforms a Workplace Benefits of TPM • Customers and visitors are impressed by these changes • Confidence in the plant’s products increases. • Overall Equipment Effectiveness (OEE) is maximized through zero breakdowns and failures, zero accidents, zero defects through total employee involvement. • Equipment reliability and maintainability as contributors to quality and productivity is increased. • TPM culture promotes zero loss activities. • TPM involves all associates from the shop floor to top management. TPM

9. Radical Transformation of a Workplace Benefits of TPM TPM

10. What does TPM Look Like?

11. What does TPM look like? Continuous Improvement Methodologies covered under TPM….. TPM

12. TPM Implemented… What Does TPM Look Like? • Machine Operators are trained to do much of the maintenance operations, and it’s part of their Standard Work TPM

13. TPM Implemented…. What Does TPM Look Like? • Necessary tools are readily available TPM

14. TPM Implemented… What Does TPM Look Like? • Equipment is modified such that it easy to keep clean, easy to see when maintenance is required. Before After TPM

15. TPM Implemented… What Does TPM Look Like? • Happy and Engaged Associates…… TPM

16. How to Implement TPM?

17. Implementing TPM…. How To Implement TPM? • Formally announce decision to introduce TPM. • Conduct TPM introductory education & publicity campaign • Create a TPM promotion organization. Companywide TPM promotion Committee Plant TPM Promotion Committee Section TPM Promotion Committee PM circles Plant Manager Section Managers Group Leaders Shop Floor Associates TPM

18. Implementing TPM…. How To Implement TPM? 4. Establish basic TPM policy and goals. • Policy – example: • Establish a profitable corporate constitution, promote TPM • Establish numerical goals – examples: • Zero breakdowns, • Zero defects, seek to maximize overall equipment effectiveness. TPM

19. Implementing TPM…. How To Implement TPM? • 5. Draft a master plan for implementing TPM. • To formulate a master plan for implementation decide what • activities must be pursued to achieve the TPM goals. • The core TPM activities are: • Focused improvement • Autonomous Maintenance • Planned Maintenance • Education and Training • Early Equipment Management • Quality Maintenance • Administrative and support department activities (Logistics & Office) • Kick off TPM initiative – should be designed to cultivate an atmosphere • that raises morale and inspires dedication. TPM

20. How To Implement TPM…. How To Implement TPM? • Build a corporate constitution designed to maximize production effectiveness. • Build an early management system for new products and • equipment. • Build a quality maintenance system. • Build an effective administration and support system. • 11. Develop a system for managing health, safety, and the environment. • 12. Sustain full TPM implementation and sustain levels. The first pillars to implement are the Focused Improvement, Autonomous Maintenance, Planned Maintenance, & Training and Development Pillars TPM

21. How To Implement TPM? Implementing TPM…. TPM

22. Implementing TPM…… How To Implement TPM? • The Eight Major Plant Losses: • Shutdown loss • Production adjustment loss • Equipment failure loss • Process failure loss • Normal production loss • Abnormal production loss • Quality defect loss • Reprocessing loss • Loss deployment • All pillars are responsible for analyzing the loss deployments for their losses. • As losses are reduced, the priority of teams selected will change TPM

23. How To Implement TPM? Implementing TPM….Machine Boards TPM

24. How To Implement TPM? Implementing TPM….Focused Improvement Pillar TPM

25. How To Implement TPM? Implementing TPM…Autonomous Maintenance TPM

26. How To Implement TPM? Implementing TPM….Autonomous Maintenance TPM

27. How To Implement TPM? | Implementing TPM…..Autonomous Maintenance Pillar TPM

28. How To Implement TPM? Implementing TPM….AM Pillar • 1. Select Equipment to work on…. • Equipment that is giving you problems with… • Unplanned downtime • Excessive quality problems • Excessive repair costs • Premature “end of life” failures • Running slower than “design” to prevent breakdowns • 2. 5S Event…. • Improve ability to perform regular inspections • Allow the discovery of potential problems • Log problems and potential problems and develop an immediate action plan • Mark all lubrication, fluid connections and directions, etc • Paint equipment TPM

29. How To Implement TPM? Implement TPM….AM Pillar 3. Defining Machine Operator Tasks • Develop Standards and Checklists – Cleaning, Lubrication, Visual Checks, Procedures to keep equipment new. 4. Make Machne Operator maintenance tasks easier/quicker • Easy to see when things need to be maintained • Lubrication needs become obvious to operator • Routine cleaning operations easier • Machine disassembly minimized • Automate maintenance when possible • Clear signals when maintenance is needed • Ensure operator training is complete • Finalize Checklist schedules TPM

30. How To Implement TPM? Implementing TPM…. Define Maintenance Tech Tasks • Provide Tech support to operator questions • Provide clear communication path • Spare Parts Program • Equip Manufacturer recommendations • Breakdown History Data • Eliminate Equipment Deterioration • Scheduled general inspections • Equipment overhauls triggered by checklists • Identify and Resolve Chronic Problems • Breakdown history log • Root cause analysis methods including 5 Whys TPM

31. How To Implement TPM? Implementing TPM…. Define Maintenance Tech Tasks • Develop and Analyze Equipment History • Plot failure history • Correlate with Equipment Quality Performance • Determine Equipment Parameters That Predict Failure • Use information from equipment manufacturer • Oil, vibration, temperature analysis • Develop Equipment Monitoring Systems • Ensure appropriate accuracy and tolerance • Lease equipment to ensure usability before purchase TPM

32. How To Implement TPM? Implementing TPM…..Autonomous Maintenance TPM

33. Implementing TPM…. PM Pillar How To Implement TPM? TPM

34. Previous Common Maintenance Strategies Benefits of TPM • Reactive Maintenance – if it is not broken do not fix it. • Preventive Maintenance – time or machine cycle based maintenance functions • Predictive Maintenance – functions on feedback that something needs to be done. • TPM – Autonomous Maintenance & Planned Maintenance The Future: TPM

35. Implementing TPM…Training & Development Pillar

36. Implementing TPM…Quality Pillar • Loss methologies in use: • Use of a QA Matrix which is a tool that prioritizes actions against the sources of defects in a process. The matrix correlates defect modes with machine parameters. The matrix identifies the location of ‘Q’ points – the points that need to be controlled to eliminate defects. • Defect Reduction Methodology • CpK Improvement Methodology

37. How to Sustain TPM?

38. Sustaining TPM…. How to Sustain TPM? • Measuring progress is key (through Steering Committee) • The Primary Measurement tool is OEE (Overall Equipment Effectiveness is measures…. OEE = Equip Availability X Performance Efficiency X Quality Rate • Build strong teams at every level and staff a promotion office • Track projects weekly from date of closure, up to 6 months then monthly for the next 6 months. When a project looses traction, the pillar team analyzes the anomaly & take corrective actions as needed. Once a project is sustained for a year, it can be removed from the KPI tracker. • Use management indicators that show everyone (at every level) what concrete progress is being made and motivate their continued involvement. TPM

39. How to Sustain TPM Application for JIPM (Japanese Institute of Plant Management Award…. • Recognized as the Global leaders in TPM • Two audits take place with Japanese auditors • In the face of growing competition, the award drives a continuous culture of improvement the focuses on cost reduction & improvement in efficiencies TPM

40. Companies that have implemented TPM Summary TPM

41. Summary….. Summary • TPM is a method for continuously improving the effectiveness of production equipment and processes by improving ‘On Demand’ availability of the equipment, through improved maintenance. • The primary focus is on involving machine operators in routine maintenance, and making that maintenance easily seen, easily done, and effective. This only happens through involvement of every single associate in every department in a factory. TPM

42. Questions TPM