advancedtpmimplementationblueprint

8/8/2019 AdvancedTPMImplementationBlueprint

1/29

TPMImpleme

ntation

Blue-Pr

int

www.tp

mquality.com

By

:MosesTan(MSc,BIT),Principa

lTPMConsulta

nt,ZenPowerInternational

ZenPo

werInte

rnationa

l

Presenta

tion.

Z


2/29

ZenPo

werInternation

al

Introduction.

W

hoWeA

re:

Z

enPowerInternationalwa

sestablishedin1995

w

ithitsregisteredofficein

Singapore.

O

urVision

.

T

obethepreferredregion

alprovideroftraining,

c

onsultancya

ndsalesservicesknown

foritsintegrity

a

ndexcellenc

einbusinessQuality,Reliabilityand

D

elivery.Z


3/29

Und

erstandingan

dUsing

Autonomous

Maintenancea

nd

OEEconcep

tforCo

ntinuous

Improvement

inman

ufactur

ing

F

ocus:


4/29


5/29

Langkah

Langkah--

1:1:Mengembalikan

MengembalikanPera

latan

Pera

latanSeperti

SepertiAsal

Asal

(Step

(St

ep--1:Res

torationEquipment)

1:Res

torationEquipment)

OPERATORS

LEADER

MAINT.

STAFF

ENGR.

STAFF

CO

NFIRMATION

OF

PROGRESS

DEPT.CHIEF

SUPERVISORS

GROUPLEADER

LISTOFEXT/INT

ABNORMALITIES

MEETI

NGTO

PLANCOUNTER

MEASURES

COUNTER

MEASURES

STE

P-1AUDIT

MODELMACHINE

MAINTENANCE

STAFF

ENGINEERING

STAFF

AUTONO

MOUS

MAINTENANCE

GROUP

FOLLOWU

PONAUDIT

FEEDBACK

COUNT

ERMEASURES

EXTEN

DEDTOALL

EQ

UIPMENT

AUDIT

DEPT.CHIEF

LEA

DER

SUPERVISORS

TONEXTSTEP


6/29

Langkah

Langkah

--2:2:Menghap

uskan

Menghap

uskanPunca

Punca

--Punca

PuncaKeko

toran

Keko

toran

(Step

(Step--2:Eli

minateConta

mination&S

tainsonArea&Parts)

2:EliminateConta

mination&S

tainsonArea&Parts)

CompleteStep-1

Step-1Sum

mary

results&findings

Wha

t?

Wher

e?

Howmuch

Why

?

AM

Team

=>70%

Countermeasures

1stPre-

Audit

byTPM

Dept.

Step-3

Present

Counterm

easures

toTPMWCand

implementation

GM/Sponsors

Audit

Ownarea

Buy-Off


7/29


8/29

Lang

kah

Lang

kah--4:4:Piawaian

PiawaianPenyelenggaraan

PenyelenggaraanAw

al

Aw

al

(S

tep4:Initial

Maintenance

Standards)

(S

tep4:Initial

Maintenance

Standards)

Mode

lm/c

passed

Step3

Initial

maintena

nce

standard

Hardto

lubricate

Hardto

check

oillevel

Abnormality

inlubrication

equipment

Abnormality

incirculation

oflubrica

tion

Equipment

gets

dirty

duringoiling

ProductManager

AM

Leader

Operator

Leader/operat

or

Counterm

easurefor

cleaningan

dchecking

Supervisor

Draftstandards

for

cleaning,

inspection&

lubrication

Engineer

&Maintenance

TrialPeriod

Attach

id

entification

label

Confirm

stand

ardfor

cleaning,

insp

ect&

lubrication

TPMdept.

P r e - a u d i t

GMaud

it

Pro

liferation

ofStep4


9/29

Preparetextsanddaily

schedule

s/checklists


schedules/checklists

Langkah

Langkah--5

:

5

:Skil

SkilPemeriksaan

PemeriksaanAmAm

(Step5:GeneralInspec

tionskills)

(Step5:GeneralInspec

tionskills)

Lubrication

Equipmentpartstightening

Pneumatics

Hydraulics

Electrical

DriveSystem

W

ater

Fireprevention/saf

ety

Lu

brication

Eq

uipmentpartstig

htening

Pneumatics

Hy

draulics

Electrical

DriveSystem

Water

Fir

eprevention/safe

ty

selectgeneral

inspectionitems

selectgeneral

inspectionitems

Manuals

Manuals

Manuals

Checklist

Checklist C

utaway

models

Cutaway

Cutaway

models

models

Revised

Maintenance

standard

s

Revised

Revised

Maintenan

ce

Maintenan

ce

standards

standards

Manager

s/supervisors

participa

teintraining

Managers/supervisors

participateintraining

Test

Test

Implement

generalIm..

TP

Moffice

Pre-Audit

TPM

office

Pre-Audit

GMAudit

GMAudit

Proliferate

Step-5


10/29


schedule

s/checklists


schedules/checklists

(Step5:Gen

eralProcess

Inspection)

(Step5:Gen

eralProcess

Inspection)

ProcessFlow

Processknowledge.

A

djustmentskills

A

bnormalitiesinP

rocess.

Processflowchart.

Pr

ocessFlow

Pr

ocessknowledge

.

Adjustmentskills

AbnormalitiesinProcess.

Pr

ocessflowchart.

SelectGeneral

Processitems

SelectGeneral

Processitems

Manuals

Manuals

Manuals

Ch

ecklists

Ch

ecklists

Cleaning

standards

Cleaning

Cleaning

standards

standards

Process

Inspectio

ns

schedules

Process

Process

Inspections

Inspection

s

schedules

schedules

Manager

s/supervisors

participa

teintraining

Managers/supervisors

participateintraining

Test

Test

Implement

generalIm..

TP

Moffice

Pre-Audit

TPM

office

Pre-Audit

GMAudit

GMAudit

Proliferate

Step-5


11/29

Langkah

Langkah--6:6:

Pemeriksaan

Pemeriksaan

Autonomi

Autonomi

(Step

(Step--6:Au

tonomousIn

spection)

6:Au

tonomousIn

spection)

Maintenan

ce

Inspectionstandards,breakdownanalysis

Op

erators

wh

o

understand

the

ir

equipment

(ab

le

tomaintain

ins

pection

standards)

Step-4

Step-4

Dailychecking,

adjustment,and

improvementof

conditionsfor

correctoperation

D

ailychecking,

adjustment,and

improvementof

conditionsfor

correctoperation

Step1

to3:

Step1to3:

Establishbasic

conditions

(cleaningand

lubrication)

Establis

hbasic

conditio

ns

(cleanin

gand

lubrication)

Step-5

Reviseprovisionalstandards

Finalisestandardsforcleaningandlub

rication

Inspectionskillcheck-up


12/29

Langkah

Langkah--7:7:Mengatur

Mengatur

Dan

DanMenguruskan

Menguru

skanTempa

t

Tempa

tKerja

Kerja

Ste

p

Ste

p--7:7:Organis

e

Organis

eandManag

eWorkplace

andManag

eWorkplace

Organiseands

etstandardsfor

:

E

QUIPMENT

PRECISION

INSPECTIONITEMS

TOOLSANDMATERIALS

FLOWA

NDSTORAGE

STANDARDSFOR

INDIVIDUALWORK

RESPONSIB

ILITIES


13/29

OEE

=

Availability*Performance

Rate*Quality

Rate

=

Maximum

100%

UnderActualManufacturingconditions,somelosses

areinevitable.HencetheBestPracticeshaveadopted

85%as

arealis

ticmonthlytarg

et.


14/29

Equ

ipmentOEELosses

EquipmentTotalAv

ailabletimein8h

rshift=480mins.

Eq

uip.PlannedD/T

=20mins

EquipLoad

ingtime=460m

ins

EquipUnPlannedD/T

=60mins

Equip.Operatingtime

EquipSp

eedPerformanceLosses.

EquipNett

Operatingtime

Equip.QualityLosses

EquipValuableOperating.time

RealMeasurabletimeVirtual/Immeasurabletime.


15/29

Calculating

Availability

in

OEE.


16/29

Equ

ipmentOEELosses

EquipmentTotalAv

ailabletimein8h

rshift=480mins.

Eq

uip.PlannedD/T

=20mins

EquipLoad

ingtime=460m

ins

EquipUnPlannedD/T

=60mins

Equip.Operatingtime

EquipSp

eedPerformanceLosses.

EquipNett

Operatingtime

Equip.QualityLosses



A B C


17/29

Availability&Utilization

Lossesd

ueto

unplanned

downtim

eonly.

Theunplanned

eventsa

reMachin

e

Breakdo

wnand

Setups.

Smallflu

ctuations.

Los

sesduetothe

samereason

splus

Pla

nneddow

ntime

...mainlydueto

no

...sch

eduleduring

...poo

rbusines

s

conditionsor

holidays,PM

shuts


18/29

Calculating

Per

form

ance

Rate

in

OEE.


19/29

Equ

ipmentOEELosses

EquipmentTotalAv

ailabletimein8h

rshift=480mins.

Eq

uip.PlannedD/T

=20mins

EquipLoad

ingtime=460m

ins

EquipUnPlannedD/T

=60mins

Equip.Operatingtime

EquipSpeedPerformance

Losses.

EquipNett

Operatingtime

Equip.QualityLosses



1.EquipBreakdownlosses.

2.EquipSetuplosses(>10min)

3.MinorStoppageslosses.

4.ReducedSpeedlosses.

5.Defectlosses

6.Yield/startuplo

sses


20/29

USEFULN

ESSO

FOEE

Provides

along-te

rmbaselineof

equipme

ntconditionforimp

rovement

measure

ment.

Whenan

OEEanalysischa

rtisplotte

d,

theexac

treasons

intermsofthe6Big

Lossesa

reclearly

understo

od.

Suitable

toolscan

beusedtoaddress

specificselectedL

osses.


21/29

M

achineType:ASA808

Monthofdata

:Oct'01

AnalysisDoneBy:CSLee

Date:2001Dec05

M

achineNumber:AM10(TSSOP14

/16ld)DataAttached:

VerifiedByTPM:KSChew

Date:2001Dec07

1-MonthSummarizedDatainMinutes

1.Totalavailabletime

=

44640min

2.Noscheduletime

=

26870min

3.Planneddowntime

=

3655min

3a.PMt

ime

=

0min

3b.Meetingtime

=

0min

3c.Housekeeping/TPM

=

3655min

4.Loadingtime=1-2-3

=

14115min

=

846900sec

5.Unplanneddowntime

=

2941min

5a.Machinebreakdown

=

2168min

5b.Engineeringtime

=

0min

5c.QC/QAtime

=

193min

5d.P.Partsshortage

=

580min

5e.Nomaterial(Lotwaiting)

=

0min

5f.Facilitystoppages

=

0min

5g.Breaktime/Nooperator

=

0min

5h.Rework/Retest

=

0min

5i.Conv./Setup

=

0min

6.Productiontime=4-5

=

11174min

7.Totalquantityprocessed(ActualO

/P)

=

33877frame

8.TCT(theoreticalcycletime)

=

109.86sec

8a.TheoreticalpossibleO/P=4/8

=

61671frame

9.MCT(machinecycletime)

=

128.32sec

9a.CurrentlypossibleO/P=4/9

=

52799frame

O

therremarks:

10.Availabilityrate

=

79.16%

Performancerate

=

69.39%

Qualityrate

=

99.80%

11.OEE

=

54.82%

TIME

R

emarks:TSSOP14/16ld=50unit/frame.

OE

E-AnalysisFormat

o u t p u t

Scale:Y-1:5

k

X-1:2.5k

10

20

30

40

50

5

10

15

20

25

30

35

40

45

60

70

80

90

100

110

TheoreticalPossibleO/P

CurrentPossibleO/P

MTBA+Idling

TotalAvailableTime

Planneddowntime+Noschedule

Loadingtime

Unplann

eddowntime

Productiontime

Speedloss

ActualO/P

Unplanneddowntime

Before

IDENTIFYTHE

MAJORLOSS

ESTHROUGH

THEOEEANALYSIS


22/29

MachineType:ASA808

Monthofdata

:Oct'01

AnalysisDoneBy:C

SLee

Date:2001Dec05

MachineNumber:AM10(TSSOP14/16ld)DataAttached:

VerifiedByTPM:K

SChew

Date:2001Dec07

1-MonthSummarizedDat

ainMinutes

1.T

otalavailabletime

=

44640min

2.N

oscheduletime

=

26870min

3.P

lanneddowntime

=

3655min

3

a.PMt

ime

=

0min

3

b.Meetingtime

=

0min

3

c.Housekeeping/TPM

=

3655min

4.L

oadingtime=1-2-3

=

14115min

=

846900sec

5.U

nplanneddowntime

=

2941min

5

a.Machinebreakdown

=

2168min

5

b.Engineeringtime

=

0min

5

c.QC/QAtime

=

193min

5

d.P.Partsshortage

=

580min

5

e.Nomaterial(Lotwaiting)

=

0min

5

f.Facilitystoppages

=

0min

5

g.Breaktime/Nooperator

=

0min

5

h.Rework/Retest

=

0min

5

i.Conv./Setup

=

0min

6.P

roductiontime=4-5

=

11174min

7.T

otalquantityprocessed(ActualO/P

)

=

(estimated)

frame

8.T

CT(theoreticalcycletime)

=

106.79sec

8

a.TheoreticalpossibleO/P=4/8

=

63444frame

9.M

CT(machinecycletime)

=

112.64sec

9

a.CurrentlypossibleO/P=4/9

=

60149frame

Oth

erremarks:

10.

Availabilityrate

=

79.16%

Performancerate

=

81.63%(etd)

Qualityrate

=

99.80%

11.

OEE

=

64.48%

TIME

Rem

arks:TSSOP14/16ld=50unit/

frame.

(estimated)

OEE-AnalysisFormat

o u t p u t

Scale:Y-1:5kX

-1:2.5k

1020304050

5

10

15

20

25

30

35

40

45

60708090100110

TheoreticalPossibleO/P C

urrentPossible

O/P

M

TBA+Idling

Total

AvailableTime

Planneddowntime+Noschedule

Loadingtime

Unplanneddowntime

Productiontime

Speedloss

EstimatedO/P

U

nplanneddowntime

IM

PROVEMENTD

ONECANBEOBSERVEDTHRO

UGHTHEOEE

ANALYSIS

After


23/29


24/29

No

Description

Delta(%

)

Before

After

*9.6

6%

112.64

12.2

2%

3

UPH

2579

29

05

12.6

4%

2

MCT

Improveme

nt

4

OEE

54.82%

64.48%

1

128.32

2.7

9%

109.86

106.79

TCT

SpeedImprovement

AM10-A

SAAutomold808

Note:Item1,2&3arecalculatedby

IEdepartment

Achieveme

nt!!

*item4

isbaseonnolossfrom

lot-waiting


25/29

ExampleOf

Imp

roving

Perform

anceR

ate

t

hrough

Improving

theEquipment

MTBA

Losse

s.


26/29

Summa

ryofS

taticR

estora

tion

A

ctivitie

s(1stP

art]

Sixstandardsstatic

conditionswerechecked

andidentifiedareas

needtobe

restored.

Indexercla

mpsparallelismwasout.

Theindexclamperandbackrailgap

wereoutofthe

requiredsp

ec.

Outputinde

xclamperpositionnotpa

rallelwhena

lead-

frameiscla

mped.

Onehotpla

tescrewwasmissing.


27/29

Before

andAfterR

estoration

M

TBA

01012141618202224

Before

Afer

Hour

* M T B A b a s e d o n l y o n A l i g n m e

n t E r r o r s t o p p a g e s

1stgoal:

3Hr.12

Min.

2ndgoal:

22Hr.40

Min.


28/29

Equipment

QualityRate

Lo

sses.


29/29

Checkedby

Preparedby

Phenomenon

nalysisChart

No1

/1

InvestigationResult

4M

Correlation,

FirstItem

InvestigationResult

4M

Correlation,

SecondItem

Investigation/

d

Temporary

Decision

Criterion

Measurement

Value

Decision

Investigation/

MeasuringMethod

Temporary

Decision

Criterion

Measurem

ent

Value

Decision

(3rd,

4th,

5th

and6thItems)

Measuring

Method

Physicalview(Logicalreasoning)

InvestigationResult

IfNG,

C

ountermeasure

Result

Temporary

Decision

Criterion

Measure-

mentValue

Decision

whyNG?Re

storation,

Replace-

m

ent,Improvement,

Remodeling

Measurement

Value

Decision

1

2

4

5

6

7

Standardization

andlinktoTPM

Maintenance

System

8

advancedtpmimplementationblueprint

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