Total Productive Maintenance (TPM)

Total Productive Maintenance (TPM)

Practical Process Improvement Practical Process Improvement Practical Process Improvement

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TPM blitz TPM blitz

Kaizen Workshop Purpose:The purpose of this Kaizen Blitz is to improve the ability to respond to customer’s demand through improved asset utilization, workplace organization and visual management.

Objectives:1. Complete Phase 1 & 2 TPM improvement activity2. Improve OEE by 25% with 2 months3. Improve Workplace Organization and Visual Management

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TPM DefinitionTPM Definition

TPMTPM is a process that maximizes the

productivity of equipment for its entire life.

TPMTPM fosters an environment where improvement efforts in Safety, Quality, Cost,Delivery and Creativity, are encouraged, through the participation of employees.

Total Productive Maintenance

“Total” means = ALL Employees

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AgendaAgenda

Day 1: Classroom training Phase 1 & 2, facility measurements & evaluations.

Day 2: Classroom training Phase 3 & 4, maintenance measurements & evaluations, for better maintenance work flow.

Day 3: Focused cleaning, sorting, inspection, modifications and/or laying out areas,for better maintenance work flow.

Day 4: Improve safety, calibration, data collection, & lubrication in facility and maintenance areas. Evaluate and measure.

Day 5: Plan long term improvements. Team to present successes and action items.

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1. Stabilize Failure Intervals

2. Improve Equipment Productivity

3. Maintenance Excellence

4. Predict Equipment Life

Ratings: 0 = No obvious application of standard 1 = Some evidence of application of standard 2 = Fully applied standard

.13

.00

.16

.16

Average

Current StateCurrent State

Was Now.39

.27

.16

.16.11 .24

66

Current StateCurrent State

77

Fluid lines & fittings leakFluid lines & fittings leakGrease fittings are dry & not coveredGrease fittings are dry & not coveredAir filters are not presentAir filters are not presentPump motors are coated with dirt / contaminationPump motors are coated with dirt / contaminationElectrical cabinet fans are coated with dirt/dustElectrical cabinet fans are coated with dirt/dustGauges are not usable, dirty and not labeledGauges are not usable, dirty and not labeledElectrical connections are loose & wires are damagedElectrical connections are loose & wires are damagedChemicals migrate causing contaminationChemicals migrate causing contaminationFasteners are corroded / strippedFasteners are corroded / strippedGuards / shields are loose or missingGuards / shields are loose or missingExcessive solid / liquid waste is underneathExcessive solid / liquid waste is underneathRoutine inspection difficult due to accessibilityRoutine inspection difficult due to accessibilityNo ownership by employeesNo ownership by employeesEHS issuesEHS issues

Equipment Condition

Current StateCurrent State

88

Top 5 FailuresTop 5 Failures

Defect % Solution

1

2

3

4

5

(Based on Team experience)

Degaste Bomba/ Friction in the pump 35% Prevent media from entering pump

Poleas & Bandas/Pulleys & belts 20% Inspect/replace based on run time

Ensure ample supply of cold water from chiller

Sello Mechanico en Molino/Seal on the Mill 5%

Fugas de tanque/Leakage from tank

Operadore no disponable 100% / Operator not available

5%

35%

Fix/replace pipes

Create checklist/walk pattern/inspection points

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Team in ActionTeam in Action

1010

Team Azub Date: 11/11/2005 Page:______ of:______

Item No. Description of Problem Counter Measure

Person Responsible Due Date

% Complete Date Complete

5s actions

1

Excessive sludge, water, trash, rusty metal, dust

Clean entire plant/Limpiar todo la planta

TEAM, OPERATORS 11/11 11/11

2

Paint is peeling, stained Paint affected parts/Pintar partas necessarias

TEAM, OPERATORS 11/11 11/11

3Slurry overflows from the Mill Repair float sensor/Instalar

sensor descarda MolinaSantiago Lopez 11/11 11/11

4

Gages air, water, temperature are unreadable Replace all affected gages Jose Martin

11/11 11/11

5 Leaking pipe under slurry tank Replace and re-seal pipes Edder Marlon11/11 11/11

6 No visual management indicators

Install signage(rotation, flow direction, equipment name, warnings) Jose Martin

11/11 11/11

OEE actions

7Agitator motors are clogged with dust which causes overheating and motor failure Clean and install filters Jorge Garcia

11/11 11/11

811/11

8 Slurry leaks from Mill pump housingChange Mill pump & rebuild old pump Gilberto Vazquez

11/11 11/11

9No indication of maintenance points (lube, fill, check, tighten) Number and list points to service Jose Martin

11/11

10Media enters the mill pump and causes premature wear on internal pump parts

Repair/ replace mesh in Mill and inspect between batches for damage Andres Medina

11 Critical parts are not always availableCreate list and purchase as required Juan Cuestas

12/1

12

Improper water temp causes seal failure on Mill

Clean chiller and install air filters

Jose Tolentino

11/11 11/11

13

Limited visibility to RPM controller (hidden in cabinet)

Re-mount controller on face of cabinet

Andres Medina

11/11 11/11

EHS actions

15

Access to pulleys/belts on agitator is poor(employee can fall) Install metal ladder/platform Contractor

11/11 11/11

16 Gate on landing over the Agitator is missing Replace the gate Gilberto Vazquez11/11 11/11

17 Guards missing multiple places Clean/replace/repair guards TEAM, OPERATORS 11/11 11/11

18Agitator loading hatch causes excessive material spills

Add a chute that will support the bag of material Contractor

11/11 11/11

Sustain actions

19Gages, switches, sensors, filters etc do not get regular attention

Inspect/repair/clean gages, sensors, floats, limit switches, filters weekly Operators

11/11

20Preventatitve maintenance is limited due to available evaluation tools

Create Tool list for Preventative TPM (include thermography and ultra-sonic equipment Raul Hernadez

12/1

21Routine maintnence is not scheduled or performed consistently

Create and display schedule with weekly audit by leadership Jose Martin

11/21

22 No weekly 5s reviewWeekly 5s review performed and reviewed by leadership team Dimitri Makres

11/21

23 No defined strategy for TPM deployment

Leadership team to particpate in TPM 2-day strategy design/planning session (See Dimitri Makres

TBD

24 No historical OEE data availableBegin tracking daily uptime/downtime and reasons Raul Hernadez Start 11/21

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1111

Leaking pipes New pipe connections

Contaminated Motor Cleaned & filter installed

ImprovementsImprovements

One thread holding the joint together!!

1212

ImprovementsImprovements

Dirty water chiller Cleaned & filters installed

Gages replacedNon-working Gages

1313

ImprovementsImprovements

Need a ladder to grease Fittings accessible without ladder

Can you see the filter? Now you can

1414

Ladder installed

New Pump installed w/ guardSolid waste under pump

ImprovementsImprovementsDifficult accessibility to belts/PM

Guard removed

1515

RPM control in cabinet RPM control accessible

Cleaned areaDirty rags and trash

ImprovementsImprovements

Open door

Control visible with door closed

1616

Angled Feed Chute

Missing safety railing Repaired safety railing

ImprovementsImprovements

Messy load area Chute

1717

TPM Focused Improvement Objectives TPM Focused Improvement Objectives -- ResultsResults

Equipment: Acme Plant Date: week 11/7

Start Target 1st Day 2nd Day 3rd Day 4th Day 5th Day Post Event%Increase/Decrease

Space (sq. ft.)

Scrap/year(concentrate)

Walking distance (ft.)

Parts travel distance (ft.)

Noise level (db)

EHS issues Visual controls

O.E.E. (%) **5’S rating

4-phase development score

Throughput timeProcess cycle time

Changeover (Total time)

Exhaust air flow (CFM)

Mistake Proofing

Changeover (Total # )

49%1.32 3.3

61%

Avg .11

9 00 15

0

Avg .25 Avg .24

** Estimated OEE based on experiential data

Note: 1425 lbs concentrate ($2591) removed with this effort

Parts volume per day

69%

3000 lbs

3.4

10 100%100%20%100%

100%

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Learnings:

1) Keep area clean allows us to see problems before they occur2) Employees area critical to TPM success3) Start a new culture of owning the process4) Safety cannot be overlooked

Benefits:

1) Reduce/eliminate scrap to save estimated $ 5,400/year2) Problems can be observed more quickly

3) Operators safety is increased

4) Process reliability improved 20%

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Next Steps

- Complete open items from Newsletter

- Management Gemba walks to sustain changes

- Management training on TPM basics

- 5S blitz on the maintenance area/warehouse (5s score is 1.67)

-TPM program design and deployment strategy(ref. Phase 3 Maintenance Excellence / Phase 4 Predictive Maintenance