tpm - tech talk

TECH TALK ON

TOTAL PRODUCTIVE MAINTAINENCE

BY SOUMYAJIT

HAZRAPGPDE

WHAT IS TPM ?TOTAL PRODUCTIVE MAINTAINENCE

TOTAL = All encompassing by maintenance and production individuals working together

PRODUCTIVE = Production goods and services that meet or exceed customers’ expectations

MAINTENANCE = Keeping equipment and plant in as good as or better than the original conditions at all times

In industry, total productive maintenance (TPM) is a system of maintaining and improving the integrity of production and quality systems through the machines, equipment, processes, and employees that add business value to an organization

HOW INDUSTRIES DEFINE IT

The term total productive maintenance is attributed to Nippon Denso in 70’s, it is a company that created parts for Toyota. However, Seiichi Nakajima is regarded as the father of TPM because of his numerous contributions to TPM

WHY IT IS REQUIRED ?

16 MAJOR LOSSES IN INDUSTRY

1. KOBETSU KAIZEN(Continual Improvement)

1. KOBETSU KAIZEN (Continual Improvement)

The principle behind is a very large number of small improvements are move effective in an organizational environment than a few improvements of large value

Policy - Practice concepts of zero losses in every activity - To achieve cost reduction targets in all resources - To improve over all plant equipment effectiveness - Focus of easy handling of operators

Target - Achieve and sustain zero loses with respect to minor stops, measurement and adjustments - It also aims to achieve 30% manufacturing cost reduction

1. KOBETSU KAIZEN (Continual Improvement)

LOSS ELIMINATION PROCEDURE

Data collection

Prioritizing

Individual data

Analysis and target setting

Improvement methodology

Implementing the tool

Plan for kaizens

Implementation

Review the result

OK

Horizontal Deployment

Not OK

1. KOBETSU KAIZEN (Continual Improvement)

2. JISHU HOZEN (Autonomous Maintenance)

2. JISHU HOZEN (Autonomous Maintenance)

-This pillar develops operator to take care of small maintenance tasks .

-Resulting skilled maintenance team to concentrate on value added and technical repairs . -The operator responsible for up keep of their equipment to prevent it from deteriorating

2. JISHU HOZEN (Autonomous Maintainence)POLICY 1)Uninterrupted operation of equipments. 2)Flexible operators to operate and maintain other equipments. 3)Eliminating the defects at source through active employee participation. 4)Stepwise implementation of JH activities.

JISHU HOZEN Targets 1)Reduce oil consumption by 50%. 2)Reduce process time by 50%. 3)Increase use of JH by 50%.

2. JISHU HOZEN (Autonomous Maintenance)

8 steps of Jishu Hozen

2. JISHU HOZEN (Autonomous Maintenance)

1. Preparation of Employees

2. JISHU HOZEN (Autonomous Maintenance)

2. Initial Cleaning of Machine

2. JISHU HOZEN (Autonomous Maintenance)3. Take countermeasures

WHITE TAG

RED TAG WHITE TAG

RED TAG

2. JISHU HOZEN (Autonomous Maintainence)

4.Fix tentative JH standards

2. JISHU HOZEN (Autonomous Maintainence)

5. General Inspection

2. JISHU HOZEN (Autonomous Maintenance)

6. Autonomous Maintenance

1) Zero failures/detects,2) Inspection efficiency improvement,3) Inspection work load balance4) Visual control.

2. JISHU HOZEN (Autonomous Maintenance)

7. Standardization

2. JISHU HOZEN (Autonomous Maintenance)

8. Autonomous Management

3. PLANNED MAINTAINENCE

3. PLANNED MAINTAINENCE

Planned maintenance is a proactive approach to maintenance in which maintenance work is scheduled to take place on a regular basis. The type of work to be done and the frequency varies based on the equipment being maintained, and the environment in which it is operating.

3. PLANNED MAINTAINENCE

It is aimed to have trouble free machines and equipments producing defect free products for total customer satisfaction.

Break down into 4 categories. - Preventive Maintenance - Breakdown Maintenance - Corrective Maintenance - Maintenance Prevention

Target - Zero equipment failure and break down. - Improve reliability and maintainability by 50%. - Reduce maintenance cost by 20% - Ensure availability of spares all the time

3. PLANNED MAINTAINENCE 11 steps approach to breakdown

4. QUALITY MAINTAINENCE

4. QUALITY MAINTAINENCEThis pillar aimed towards

• Customer delight through highest quality • Defect free manufacturing• Eliminating non conformances in a systematic manner • Reactive to proactive like (quality control to quality assurance)

Benefits

1. Defect free condition and control of equipments2. QM activity to control quality assurance3. Focus of prevention of defects at source4. Focus on poka-yoke (fool proof system)5. In line detection and segregation of defects6. Effective implementation of operator quality assurance7. Achieve & sustain customer complaint zero

4. QUALITY MAINTAINENCEPolicy :Defect free conditions and control of equipments.QM activities to support quality assurance.Focus of prevention of defects at sourceFocus on poka-yoke. ( fool proof system )In-line detection and segregation of defects.Effective implementation of operator quality assurance.Target :Achieve and sustain customer complaints at zeroReduce in-process defects by 50 %Reduce cost of quality by 50 %.

Quality defects are classified as customer end defects and in house defects. For customer-end data, we have to get data onCustomer end line rejectionField complaints.

5. EDUCATION AND TRAINING

5. EDUCATION AND TRAINING

This pillar aimed towards

• Developing multi skill employees whose morale is high and who has eager to come to work and perform all required functions effectively and independently

• Employees will be trained to address the problem by finding the root cause & eliminating them

• The goal is to create a factory full of experts

Benefits

1. Achieve and sustain zero losses due to lack of knowledge /skills /technique

2. Remove fatigue and make work more enjoyable

3. Upgrading the operating & maintenance skills

5. EDUCATION AND TRAINING

It is aimed to have multi-skilled revitalized employees whose morale is high and who has eager to come to work and perform all required functions effectively and independently. Education is given to operators to upgrade their skill. It is not sufficient know only "Know-How" by they should also learn "Know-why"The different phase of skills :

Phase 1 : Do not know.

Phase 2 : Know the theory but cannot do.

Phase 3 : Can do but cannot teach

Phase 4 : Can do and also teach.

5. EDUCATION AND TRAININGPolicy :Focus on improvement of knowledge, skills and techniques.Creating a training environment for self learning based on felt needs.Training curriculum / tools /assessment etc conductive to employee revitalizationTraining to remove employee fatigue and make work enjoyable.

Target :Achieve and sustain downtime due to want men at zero on critical machines.Achieve and sustain zero losses due to lack of knowledge / skills / techniquesAim for 100 % participation in suggestion scheme.

6. DEVELOPMENT MANAGEMENT

6. DEVELOPMENT MANAGEMENT This pillar aimed towards

• Collection & utilization of feedback information regarding present products before the start of the design.- like MP sheet.

• Measuring needs for “ Easy of manufacturing “ by analyzing the process for present products.

• Measuring needs for “ Easy of manufacturing” by analyzing process of new products in the stage of planning & design of products.

By identifying failures possibilities based on design reviews of new products.

By identifying failures possibilities based on trail manufacturing & test of new products.

Benefits 1. Reduces lead time to new product launch 2. Reduce the losses 3. Cost effective

6. DEVELOPMENT MANAGEMENT Need For Development Management

1. It takes too much time for installation of a new machine

2. There are too many troubles while installation

3. There is a mismatch on many parameters

4. It takes too much time to achieve the rated out put

5. It takes more amount of money than the budget

6. Sometimes, some of the improvements done have to be repeated

7. SAFETY , HEALTH AND ENVIRONMENT

7. SAFETY , HEALTH AND ENVIRONMENTThis pillar aimed towards

• CREATE SAFE WORK PLACE AND SAFE WORK PRACTICE

• THIS PILLAR PLAY VITAL ROLE WITH OTHER PILLARS ON REGULAR BASIS

Benefits

• ZERO ACCIDENT

• ZERO FIRES

• ZERO HEALTH DAMAGES

• SAFE WORKING CONDITION

• SAFE WORK PRACTICE

7. OFFICE TPM

7. OFFICE TPMThis pillar aimed towards

• To improve productivity

• Efficiency in the administrative functions and identify to eliminate losses

• Analyzing processes and procedures towards increased office automation

Benefits

• Inventory reduction

• Lead time reduction of critical process

• Equalizing the work load

• Retrieval time reduction (reduce repetitive work)

• Better utilized work area

• Reduction in administrative costs