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1、*,,Click to edit Master title style,Click to edit Master text styles,SeClick to edit Master text styles,Second level,Third level,Fourth level,Fifth level,cond level,The Lean Enterprise,Introduction to TPM Total Productive Maintenance,Lean Foundations,Continuous Improvement Training,,Learning Objecti

2、ves,Learn the basic philosophy of TPM,ExplainOEE and how it contributesto a TPM project,explore OEE components;defineand calculateOEE,List 6major components of equipment loss,Reviewand adopt the7 stepsto AutonomousMaintenance,,TPM The Need,ProcessIndustry relies heavily onequipment thatis integrated

3、and runs continuously,When down,los,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,,TPM The Philosophy,TPM aims at using equipmentto itsmaximumand aids

4、 in reducingLife Cycle Costs(LCC),In other words-going all out to eliminate the Losses(Waste)causedby theequipment,TPM improves work activitiesthat deal with Equipment Set-up,Operating parameters,Maintenance,Tear down,Repairs andBreakdowns,It specifically aimsat thecomplete eliminationof the,six maj

5、or losses while striving for a goal of zero unscheduled downtime,,TPM -The SixMajorLosses(Waste),Downtime Losses,(1)Equipmentfailures,(2)Set-up andadjustments,Speed Losses,(3)Idling andminorstoppages,(4)Reduced speed(actual operating,vs.designed),DefectLosses,(5)Defects inprocess,(6)Reduced yield be

6、tween start of,production andstableproduction,,OEE Formulas,1.Unexpected Eq.Breakdown,2.Set-up&adjustments,3.Idling andminor stoppages,4.Reduced speed,5.Defects inProcess,6.Reduced Yield,Overall Equip.,Effectiveness:,Availability,example:,Efficiency,example:,RatioofQuality,Products,example:,Load Dow

7、nTime,Load Time,460min 60min,460,TheTheoreticalCy,cle,Time xProcessed Qty,OperatingTime,0.5/unitx400units,400minutes,ProcessedAm,oun,t,AmountofDefects,ProcessedAmount,400,8,400,x 100%,=,87%,x 100%,=,50%,x 100%,=,98%,=,=,=,.,87x.50 x.98=46.2%,LossMeasureFormulaMetric,,OEEPareto Analysis by LossCatego

8、ry,Overall,Equipment,Effectiveness,Loss,3&4,46.2%OEE,Loss,1&2,Loss,5&6,,TPMattacks6 major“Losses,”,”plusElimination of other Wastes,(Mura,Muri,Muda),OperatorTime Losses,Manpowerlossesdue to operationtime being donemoreslowlythanstandardtime(CycleTime StandardTime),MaterialLosses,Lossesinyielddue to

9、inherentwaste(cut-offstock,set-uppieces,prototype,etc),Energylosses suchaselectricity,gas,and water whenmachinery is notdoingvalue-addedwork,Idlinglosses duetoinadequate sensorsand productbuilduponconveyorsand chutes,,Best PracticesWorld-ClassGoals(ATPM,“,“Vision”),BeforeAfter,Availability87%90%,Per

10、formanceEfficiency50%95%,RatioofQuality(Yield)98%99%,Overall Eq.Effectiveness42.6%85%,,TPM,OperationalGoals(Qualitative),Increasenumberofsuggestions,Improve level of teamwork of shopfloor,Improve cross-functionalteamwork,Establishmaintenancethroughoutthetotalequipment lifecycle,Peoplemaintaintheirow

11、n equipment,Machinesavailablefor just-in-time(JIT)application,Improve machineavailability,Improve workingenvironment(6S),Improve Corporateculture andimage,Improve Business performance,,TPM,OperationalGoals(Quantitative),Cost Reductions,Actualand to be reduced,Energysavings,Maintenance,EquipmentEffic

12、iencies,Zero failures(ultimategoal),MTBF(mean timebetweenfailures),MTTR(mean timebetweenrepairs),Idle Time,,TPM,OperationalGoals,cont.(Quantitative),Safety,Zero accidents,Quality,Zero failures,Zero complaints,Education,Hoursoftraining/number of sessions,NumberofKAIZEN projects,NumberofSuggestions,,T

13、PM,Definition of Total,TotalEffectiveness,Reductionin lossesof all equipment tooptimize its effectiveness andimprove costs,TotalMaintenance,Involves the whole maintenancesystem inclusive ofequipmentmanufacturer,equipmentengineering,and equipment user toimprove maintainability,TotalParticipation,Ever

14、yone has aroleto make TPM work,Managementto set policy,Middle management,staffto supportandlead,Maintenance tomaintain and train,Operatorsto take onnewmaintenance challenges,,TPM Roleof MaintenanceFunction,Provides technical support forautonomous maintenance done by operators,Restores deteriorated e

15、quipment throughchecks,inspections,andoverhauls,IdentifiesDesign weaknesses and improves theequipmentto error-freefunction(via poka-yoke),Improves technical maintenanceskills for checks,inspections,and overhauls,,TPM Roleof Operator Function,Maintainsbasiccondition(cleaningandlubrication),Maintainsp

16、roper condition andstandardsforequipmentusage,Partiallyrestores deterioration,Basicskill levels in:,Changeoverandset-up,Reductionof minor stoppages and adjustments,,TPM Autonomous Maintenance,Definition:,Operationsmaintainsitsown equipment,Utilize 7-stepplan*,(*Source:JapanInstituteof PlantMaintenance),,7 Steps toAutonomous Maintenance,Step1 Initial clean-up(External),“Kick-off”program,Closely alignedwith6S(5S+1),ManagementandStaffshowcommitment,Clean,Sand andPaint,Identify sources ofdefects:,Ga