1.tpm awareness information en

3,466 views

Published on

Published in: Business
0 Comments
2 Likes
Statistics
Notes
  • Be the first to comment

No Downloads
Views
Total views
3,466
On SlideShare
0
From Embeds
0
Number of Embeds
1,551
Actions
Shares
0
Downloads
65
Comments
0
Likes
2
Embeds 0
No embeds

No notes for slide

1.tpm awareness information en

  1. 1. 1 Courtesy, in part, of Motorola SPS. Thank You! Welcome To Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  2. 2. 2 Courtesy, in part, of Motorola SPS. Thank You! About T.P.M. After World War ll. Japanese industries determined that to complete successfully in the world market they had to improve the quality of their products. to do so, they imported management and manufacturing techniques from United States and adapted them to their circumstances. Subsequently, their products became known throughout the world for their superior quality, focusing world attention on Japanese- style management techniques. TPM DEVELOPMENT PROGRAM Implementing Total Productive Maintenance Seiichi Nakajima. Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  3. 3. 3 Courtesy, in part, of Motorola SPS. Thank You! WHAT IS T.P.M. ?? Definition of T.P.M : T.P.M. IS: A PRODUCTIVE MANUFACTURING SYSTEM with the TOTAL Participation of: Managers, Supervisors, Engineers, Technicians and Operators. T.P.M. Includes the Following Benefits: • Maximize Overall Equipment Effectiveness • Establishment a Complete System of Maintenance for the Machine Entire Life • Create a Better Work Environment, Promoting the Participation for All Employees Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  4. 4. 4 Courtesy, in part, of Motorola SPS. Thank You! T.P.M. = Medical Science of Equipment PRODUCTION Foton AUTOMATION B-820 VIDEO-AUTO DIE-BONDER MODEL 8030A POWER HEATER Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  5. 5. 5 Courtesy, in part, of Motorola SPS. Thank You! The Main objective of TPM is : Zero Interruptions Zero Defects Zero Accidents Throughout total employees participation from Top Management to Operators, based in the following activities: Autonomous Maintenance • Planned Maintenance • Individual Improvement • Quality Maintenance • Early Equipment Management • Education/Training (People Development) • Safety Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  6. 6. 6 Courtesy, in part, of Motorola SPS. Thank You! PILLARS OF TPM A U T O N O M O U S M A I N T E N A N C E Q U A L I T Y M A I N T E N A N C E P L A N N E D M A I N T E N A N C E I N D I V I D U A L I M P R O V E M E N T T R A I N I N G P E O P L E D E V E L O S A F E T Y E H S E A R L Y E Q U I P M A N A G E M E N T P 5S´s Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  7. 7. 7 Courtesy, in part, of Motorola SPS. Thank You! T.P.M. Total Productive Manufacturing People , Equipment and Product Improvement by Working Together. EXCELLENCE Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  8. 8. 8 Courtesy, in part, of Motorola SPS. Thank You! PLANT OVERVIEW PLANT OVERVIEW Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  9. 9. 9 Courtesy, in part, of Motorola SPS. Thank You! TPM Self Assessment PLANT OVERVIEW TPM Self Assessment Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  10. 10. 10 Courtesy, in part, of Motorola SPS. Thank You! TPM Self Assessment Background: ∆ 1991 First attempt to implement TPM. ∆ TPM consultant provides training to selected Managers, Supervisors and Engineers. ∆ One coordinator with experience in Process and Maintenance is assigned to lead TPM. ∆ Literature and materials, prepared and distributed.  Lack of support and involvement results on failing the implementation. Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  11. 11. 11 Courtesy, in part, of Motorola SPS. Thank You! TPM Self Assessment 1996 ∆ One Staff Mgr. is assigned to lead the TPM Implementation plant wide. ∆ A core team is formed on 2Q/96 with key people from different departments to coordinate the implementation. ∆ Model equipment is selected based on bottle neck operation. ∆ Equipment conditions analysis performed. ∆ Most of the teams cover the initial cleaning. ∆ Activities are focused on six big losses detected and 5 S´s implementation. Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  12. 12. 12 Courtesy, in part, of Motorola SPS. Thank You! Asia Benchmarking PLANT OVERVIEW TPM Self Assessment Asia Benchmarking Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  13. 13. 13 Courtesy, in part, of Motorola SPS. Thank You! TPM Benchmarking Asia Facilities Facility 1 April 1996 Facility 2 Facility 3 Committee: Objective: Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 May June 4 Chosen Folks Learn from Asia success experiences in TPM implementation and come up with directions for Plant implementation. TPM Awareness Information
  14. 14. 14 Courtesy, in part, of Motorola SPS. Thank You! Benchmarking Conclusions  Total management involvement.  T.P.M. Manager (dedicated).  A well defined implementation process.  Provide people with time to work on it. ( 4- 6 Hr./wk ).  Each staff has their own T.P.M. Promoter full time.  Focused in Consultant X model.  Focused in just one product line per area.  Budget assigned for consulting and external training. Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  15. 15. 15 Courtesy, in part, of Motorola SPS. Thank You! TPM PLANT OVERVIEW TPM Self Assessment Asia Benchmarking TPM Implementation Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 Implementation TPM Awareness Information
  16. 16. 16 Courtesy, in part, of Motorola SPS. Thank You! IMPLEMENTATION/CONSULTANT * Q3 1996, Consultant X is selected to be Consultant. * Training of Managers, Team leaders and Team members * Master Plan Defined * TPM. implementation initiated according to Consultant X recommendations Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  17. 17. 17 Courtesy, in part, of Motorola SPS. Thank You! T.P.M. POLICY # ESTABLISH AN INTEGRATED STRUCTURE TO PROMOTE T.P.M. AS A COMPANY CULTURE. # MAXIMIZE OVERALL EQUIPMENT EFFECTIVENESS # TOTAL EMPLOYEE INVOLVEMENT. # CULTIVATE EQUIPMENT & PROCESS RELATED EXPERTISE THROUGHOUT SHOP FLOOR. ( Autonomous Maintenance, Planned Maintenance etc..) # ESTABLISH A RELIABILITY AND MAINTAINABILITY SYSTEM TO MAXIMIZE EQUIPMENT LIFE TIME. (Planned Maintenance Autonomous Maintenance, Individual Improvement, Early Equipment Management.) # ALL EMPLOYEES MUST PARTICIPATE IN T.P.M TRAINING PROGRAM. # ALL AREAS MUST FOLLOW T.P.M. ESTABLISHED GUIDE LINES. # DEPARTMENT HEAD IS RESPONSIBLE TO ACCOMPLISH AND SUPPORT T.P.M. GOALS. Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  18. 18. 18 Courtesy, in part, of Motorola SPS. Thank You! T.P.M. PLANT WIDE STRUCTURE TPM T.P.M. Office Responsible Plant Manager 5 ´s Autonomous Maintenance Planned Maintenance Individual Improvement Quality Maintenance Early Equipment Management Safety Training People Development Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  19. 19. 19 Courtesy, in part, of Motorola SPS. Thank You! PROMOTION STRUCTURE (OVERLAPPING SMALL GROUPS) PLANT MANAGER STAFF MANAGERS OPERATIONS TPM PILLARS & PROMOTION OFFICE TPM PROMOTERS Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information DEPARTMENT MANAGERS DEPARTMENT SUPERVISORS TPM TEAM
  20. 20. 20 Courtesy, in part, of Motorola SPS. Thank You! VISION STATEMENT: TPM PLANT WIDE IMPLEMENTATION Q1 2000 Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  21. 21. 21 Courtesy, in part, of Motorola SPS. Thank You! T.P.M. IMPLEMENTATION ACTIVITIES MANAGER TEAMS Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  22. 22. 22 Courtesy, in part, of Motorola SPS. Thank You! PREPARATION / PLANNING STAGE # DEFINE PILOT LINES # AMOUNT OF MACHINES INCLUDED PER LINE # DEFINE CORE TEAM MEMBERS OF EACH LINE # SELECT TEAM MEMBERS PER MACHINE # START ACTIVITIES IN PILOT MACHINES (bottle neck.) Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  23. 23. B-820 B-609 V-701 23 Courtesy, in part, of Motorola SPS. Thank You! Line and Machine Selection B-820 Machine 1 Machine 2 N-661 POWER HEATER Machine 3 Machine 4 B-609 V-701 Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  24. 24. S T A R T T A TPM Implementation Plan ACTIVITIES DEFINE STRATEGIES 1996 1997 1998 1999 2000 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 PREPARATION STAGE MASTER PLAN ORGANIZATION INTRODUCTION TRAINING PUBLICITY 1 T P M 2 3 I M P L E M E N T A MODEL MACHINES Machine 1 Machine 2 Machine 3 Machine 4 EXTEND IMPLEMENTATION SIMILAR PRODUCTION LINES K I C K O F F AUTONOMOUS MAINTENANCE & REDUCE 6 BIG LOSSES EXTEND SIMILAR MACHINES 30% to 50% T I O N R G E T COMPLETE IMPLEMENTATION DEFINED AREAS 100%
  25. 25. TPM 90 Days Explosion Plan October November December ww40 ww41 ww42 ww43 ww44 ww45 ww46 ww47 ww48 ww49 ww50 ww51 ww52 Machine 1 PILOT TEAM Step 3 Planned maintenance 6 big losses Individual Improvement Start Start Start Start 10 Extension teams 19 Extension teams step 1-2 Start step 1 4 mc 7 mc 3 mc 6 mc 3 mc 6 mc Machine 2 PILOT TEAM Step 2-3 Planned maintenance Start Start 6 big losses Individual Improvement Step 1 Step 2 Step 1 11 Extension teams step 1-2 B-613 3 mc 2 mc 2 mc B-601 L-604 Machine 3 PILOT TEAM Step 2-3 Planned maintenance 6 big losses Individual Improvement Start Start Start Start 6 Extension teams 2 Extension teams Machine 4 PILOT TEAM step 1-2 Start step 1 Step 1-2 Start Start 2 mc 4 mc Planned maintenance 6 big losses Individual Improvement Start Start Start 4 extension teams Start step 1 a-820 a-821 J-701 J-601 PILLARS IMPLEMENTATION MODEL GANTT TPM Activity Board Extension Teams Server Data collection M1 M2 M3 M4 GM Audit Team presentations TPM Office Audit Consultant visit TPM Meeting Local BOOT CAMP TPM MCOE MEETING, JAPAN Pillars meeting
  26. 26. M C O D E N I A L M M E N T T I R E S I S T A N C E E X P L O R A T I O N 26 Courtesy, in part, of Motorola SPS. Thank You! T.P.M. TRANSITION CURVE POLICIES DEVELOPMENT T.P.M. PROMOTION OFFICE START MANAGEMENT MACHINES FOCUS IN FEW EQUIPMENT T.P.M. PROMOTION DELEGATION INCLUDE T.P.M. IN PERFORMANCE MANAGEMENT PLAN. INCLUDE T.P.M. IN JOB KICK OFF FOCUS TRAINING SUCCESS STORIES 5 S´s CONSULTANT IN DESCRIPTION. ACCELERATED DEPLOYMENT. CONSULTANT OUT DEVELOP DATA COLLECTION SYSTEM ATTENTION TO FOCUS TEAMS TRAINING DEPLOYMENT IMPLEMENTATION PLAN RESOURCE IMPLEMENTATION GOALS SETTING FOR ALL ORGANIZATION. LOOK FOR ADDITIONAL WAYS TO DEPLOY T.P.M. FINISH CONFLICT WITH THE CULTURE ORGANIZATION ALIGNMENT REWARD SYSTEM CONTROL CHAOS Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  27. 27. 2X 27 Courtesy, in part, of Motorola SPS. Thank You! KEY GOALS 1.- TOTAL EQUIPMENT EFFECTIVENESS A) Equipment Breakdown B) M.T.B.A. C) M.T.B.F. 2.- REJECT CAUSED BY LINE EQUIPMENT 3.- LINE REJECT RATE 4.- CYCLE TIME 5.- FATAL ERROR AT CUSTOMER 6.- ON TIME DELIVERED 7.- MANUFACTURING COST % HOURS/MONTH MINUTES HOURS PPM % DAYS # OF % USD 85 1/10 1x10x 1x2x 1/5 1/5 0.8X 0 98 20% LESS 8.- LABOR PRODUCTIVITY Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 K.UNITS /# OF D/L TPM Awareness Information
  28. 28. 28 Courtesy, in part, of Motorola SPS. Thank You! AUTONOMOUS MAINTENANCE. MANUFACTURING SPECIALIST Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  29. 29. 29 Courtesy, in part, of Motorola SPS. Thank You! AUTONOMOUS MAINTENANCE IS: Maintenance performed by equipment operators. THE FIRST 3 STEPS OF AUTONOMOUS MAINTENANCE. STEP # 1 INITIAL CLEANING. STEP # 2 COUNTERMEASURES FOR THE CAUSES OF FORCED DETERIORATION AND IMPROVING HARD-TO-ACCESS AREAS . STEP # 3 MAKING A TENTATIVE CLEANING/ LUBRICATION STANDARD. Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  30. 30. 3 7 2 30 Courtesy, in part, of Motorola SPS. Thank You! AUTONOMOUS MAINTENANCE 5 4 Selection Formats: Daily Cleaning & Initial Inspection Hot Spots, CAP-DO 5W´s Develop One Major Problems Point lesson 6 Put F Tags Step # 1 Initial Cleaning Standardization Cleaning / Lubrication Initial Cleaning (Inspection) Training in One Point Lesson Photos Before Photos After 1 8 Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  31. 31. 3 7 31 Courtesy, in part, of Motorola SPS. AUTONOMOUS MAINTENANCE 5 Thank You! 4 Put “F” Tags Failures Analysis Why´s Analysis Actions in Sources of Contamination & Hard access areas Step # 2 6 Find & List Areas of Hard Access Sources of Contamination & Hard Access Areas Modify Covers For Easy Visualization & Quick Disassemble Find & List Sources of Contamination Remove “F” Tags Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 2 Initial Inspection Final Inspection (Audit) 1 TPM Awareness Information 8
  32. 32. 4 6 3 7 3 32 Courtesy, in part, of Motorola SPS. AUTONOMOUS MAINTENANCE 5 Thank You! Verify actual time Improve time of execution Detail activities Vs estimated Put “F” Tags (Establish time & frequency) Step # 3 Tentative Standards Remove “ F” Tags Cleaning / Lubrication implementation Apply activities to similar machines 2 2 Develop tentative standards 8 1 Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  33. 33. 44 34 27 1 2 33 Courtesy, in part, of Motorola SPS. Thank You! TPM Teams Status October 1997 • Number of Hot Spots detected: • Number of Hot Spots solved: • One Point Lesson developed: • One Point Lesson Taught: • Number of teams on TPM: • Teams on step 3: • Teams on step 2: • Teams on step 1: 284 126 24 Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  34. 34. 34 Courtesy, in part, of Motorola SPS. Thank You! PLANT OVERVIEW TPM Self Assessment Asia Benchmarking TPM Implementation Expansion Plan Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 Expansion Plan TPM Awareness Information
  35. 35. 1 9 9 8 35 Courtesy, in part, of Motorola SPS. Thank You! T.P.M. DEPLOYMENT L I N E F L O W CURRENT EQUIPMENT IN T.P.M. SAME KIND OF EQUIPMENT 1999/2000 EXPANSION 1997 Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  36. 36. Line 36 Courtesy, in part, of Motorola SPS. Thank You! PROJECTED PROGRESS IN TEAMS Q-1’ 98 A.M. STEP # 1 A.M. STEP # 2 A.M. STEP # 3 Wafer Process Line 1 Line 2 Line 3 Line 4 Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 11 03 03 04 TPM Awareness Information 16 11 08 01 03 01 01 01
  37. 37. 37 Courtesy, in part, of Motorola SPS. Thank You! T.P.M. FOLLOW-UP TEAMS PRESENTATION TEAMS AUDITS TEAMS MEETING Consultant X MANAGERS VISITS PRESENTATION 6 TEAMS PER MONTH 6 TEAMS PER MONTH WEEKLY TWO DAY EVERY TWO MONTHLY MEETING MONTHS Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  38. 38. 38 Courtesy, in part, of Motorola SPS. Thank You! PLANT OVERVIEW TPM Self Assessment Asia Benchmarking TPM Implementation Expansion Plan Pilot Team Case Study Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 Pilot Team Case Study TPM Awareness Information
  39. 39. 39 Courtesy, in part, of Motorola SPS. Thank You! PILOT MACHINE N-62361 Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  40. 40. 40 Courtesy, in part, of Motorola SPS. Thank You! Defectives 30 25 20 23 20 25 22 18 20 21 17 19 23 15 10 5 5 7 8 6 5 9 6 3 4 3 3 2 4 6 8 6 5 4 7 6 0 N-662361 N-61162 N-634766 JAN 96 JUN FEB JUL MAR AUG APR SEP MAY OCT 96 Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  41. 41. %T.C. ENE./96 MAR MAY JUL OCT./96 ABR %T.C. ABR AGO ENE./96 AGO MAR MAY SEP FEB JUN JUL SEP FEB JUN OCT./96 %T.C. FEB JUN AGO MAR OCT./96 ENE./96 MAY ABR JUL SEP 41 Courtesy, in part, of Motorola SPS. Thank You! DOWN TIME 25% 23% 23% 20% 20% 20% N-662361 15% 10% 17% 18% 12% 15% 18% 18% 5% 0% 25% 20% N-663242 15% 10% 5% 12% 11% 10% 11% 8% 9% 7% 6% 8% 10% 0% 25,00% 20,00% 15,00% N-649666 10,00% 5,00% 7,50% 8% 4% 7% 9% 5% 3% 5% 6% 8% 0,00% Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  42. 42. 42 Courtesy, in part, of Motorola SPS. Thank You! CLEANING IS INSPECTION.... 5’S AUTONOMOUS MAINTENANCE Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  43. 43. 43 Courtesy, in part, of Motorola SPS. Thank You! INSPECTION IS DETECTION. CRASH Broken Part Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  44. 44. 44 Courtesy, in part, of Motorola SPS. Thank You! PRESSURE CORRECT INCORRECT TO MUCH PRESSURE CORRECT GAUGE ALIGNMENT INCORRECT NO Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  45. 45. 45 Courtesy, in part, of Motorola SPS. Thank You! CORRECT CENTERING INCORRECT Dummy Part CORRECT SYMMETRY Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information INCORRECT BENT
  46. 46. 46 Courtesy, in part, of Motorola SPS. Thank You! CONTACT CORRECT INCORRECT Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  47. 47. 47 Courtesy, in part, of Motorola SPS. Thank You! TO STANDARDIZE AND PREVENT RECURRENCE One Point Lesson Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  48. 48. 48 Courtesy, in part, of Motorola SPS. Thank You! MACHINE PERFORMANCE Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  49. 49. Abr May Oct-96 Sep-96 Dec-96 Jan-97 Ago Mar Feb Jun Jul %D.T. Nov-96 Apr May Dec-96 Jan-97 Feb Oct-96 Mar Aug Sep Jun Jul Sep 49 Courtesy, in part, of Motorola SPS. Thank You! Defectives 25 20 15 23 18 “ ZERO” 10 10 6 Defectives 5 3 1 2 0 0 0 0 0 0 25% 20% 18% DOWN TIME 20% P.C. BOARD DAMAGED 15% 15% 12% 10% 5% 9% 8% 7% 5% 6% 4% 3% 3% 0% Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  50. 50. 3 50 Courtesy, in part, of Motorola SPS. Thank You! WHAT IS NEXT? 6 Big LINK Losses 4 4 Autonomous Maintenance Planned Maintenance Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information
  51. 51. 51 Courtesy, in part, of Motorola SPS. Thank You! Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information

×