5 days TPM Workshop/Implementation Strategies at F&N
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Implementing Total Productive Maintenance (TPM) towards being World Class in Equipment Maintenance. Our Goal is towards a Zero Downtime,Zero Defects, maximizing Production time to delight our Customers by our commitment to deliver Productivity & 1st Class Quality with on time Delivery towards 21st Century Business of Delighting our Customers.
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5 days TPM Workshop/Implementation Strategies at F&N
- 1. F&N Dairies Pulau Indah Klang TPM Assessment/ Implementation Towards World Class Manufacturing timothywooi2@gmail.com No part of this training manual may be reproduced.
- 2. • Principal Consultant for Lean Management. Certified TPM & Kaizen Specialist with 30 over years working experience. • Provides Technical Consulting Services on TPM, Kaizen and Cellular System set up. • A Mechanical background Green Innovator recycling and reusing Idle resources to eliminate waste to add Value to promote Green. • Founder of Tim’s Waterfuel, an alternative Hydroxy Fuel supplement using Water that adds power and reduce Co2 emission on automobiles. • An NGO Community worker for Prison, Drug Rehabilitation and CREST North (Crisis Relieve & Training) Malaysia, an organization that respond to Crisis & Flood. Timothy Wooi Add: 20C, Taman Bahagia, 06000, Jitra, Kedah Email: timothywooi2@gmail.com H/p: 019 4514007 (Malaysia)
- 3. Introduction • Yourself • Your name ? • Department / Section Why are you here? Parable of the Pencil.
- 4. TPM Implementation Planning and Preparation: 1. Top management commits to TPM implementation 2. Introductory Education and Training 3. Establish TPM promotion organization 4. Value stream map and select pilot model 5. Collect OEE data / Select a Baseline 6. Set basic policies and targets 7. Create master plan for TPM implementation 8. TPM kickoff
- 5. Full TPM Implementation Implementation 9. Establish system to improve production efficiency – Autonomous Maintenance (Workshop) – Kaizen – Planned Maintenance – Skill enhancement – Small Group Activities 10. Early equipment management 11. Establish a quality maintenance system 12. Improve operation efficiency in the office environment 13. Establish safety, hygiene and working environmental protection system 14. Total application of TPM and raising the level
- 6. TPM Strategy Day 1 – Team Charter/ formation and TPM kick-off – Establish TPM policies, TPM schedule steps – Gather Info/data for AM checklist, – Clean n Inspect, Clean, Oil, Dirt Day 2 – Re access maintenance activities, gather data and validate info for A.M. Check - pictures before. – Identify Improvement Activities Day 3 – Focused Improvements(Kaizen) – Improvement Action Plan-Clean, Dust, Oil – Preparation for Improvement Projects Action List Proposal/AM Training Day 4 – AM Training/Action Implementation – Document Report using standard formats Day 5 – Report Out & Presentation
- 7. Day 1 Morning TPM policies,6 Steps to TPM Installation • Establish basic TPM policies and SMART goals. Analyze the existing conditions and set goals that are SMART. (Gather Info for AM checklist, Clean n Inspect) • 6 Steps to TPM Installation (until Clean & Inspect) • TPM kick-off. Implementation will begin at this stage.
- 8. Noon Cleaning and Inspection • Log Out Tag Out on Machine. • Actual Cleaning and Inspection of Machine to externalize to Autonomous Maintenance. Operators routine cleaning and inspection will help stabilize conditions and stop accelerated deterioration. (reference Clean & Inspection Checklist for Production Machine)
- 9. Day 2 Morning Autonomous maintenance for Operators • Develop an autonomous maintenance program for Operators. • Create a DAILY Autonomous Maintenance Checklist, (Use Visual Roadmap/log out tag out procedures/TPM Board) Operators routine cleaning and inspection will help stabilize conditions and stop accelerated deterioration. (Reference: AM Cleaning and Inspecting followed by AM Checklist for Printing Machine)
- 10. Noon Assessment/Improvements • Identify problems found during Clean & Inspect. • Identify Improvements projects for Moonshine activities – improve 5S – Address dust – Oil n Lubrication (Reference: AM Cleaning and Inspecting followed by AM Checklist for Production Machine)
- 11. Day 3 Focused Improvements (KAIZEN) • Improvement Action Plan-Clean, Dust, Oil Identify causes of Dust and Contamination and Brainstorm actions to address n prevent occurance • Preparation for Moonshine Projects Action List Proposal/AM Training (Use 1H n 4 WHs approach to identify root cause.)
- 12. Day 4 AM Training and Action Implementation • AM Training/Action Implementation • Document Report * (Use Target & Scope, Before n After Cartoon &Kaizen Newspaper to record activities with Pictures with Road Map & Visual identifications for AM. on TPM Board).
- 13. Day 5 Report Out and Presentation • Report out presentation. – Objective/Target and Scope – Improvement Cartoon – Kaizen Newspaper – Review
- 14. Where are we today? Is most of your time spent fire fighting? Are equipment failures and quality issues a problem? Is very little time spent on preventing the failures and quality defects from occurring? Do you have institutionalized rework in your facilities?
- 16. Why TPM? • TPM combines the traditionally American practice of Preventive Maintenance with Total Quality Control and Total Employee Involvement, to create a culture in which the user partners with the Maintenance in maintaining the Equipment towards a “ready to use condition” using energy efficiently. • It is a company-wide team-based effort to build quality into equipment and to improve overall equipment effectiveness
- 17. Why Implement TPM? Cost Reduction for Survival Strict Quality Demands World ClassDiversification of Needs, Shorter Delivery Time Change Work Environment Reduce cost dramatically by pursuing the extreme in equipment (production) effectiveness Establish conditions that will not allow defects and manage conditions that will prevent defects Create unmanned operations and people friendly working equipment Minimize machine setup time and get the product to the customer on time World Class Qualifiers
- 18. Set-Up and Adjustment Idling and Minor Stoppage Reduced Speed Quality: Defects in Process & Rework Reduced Yield Equipment Failures Easy to measure Low impact on profit High impact on profits Labor Materials/spares Outside services Maintenance overhead Equipment Production Losses (Six Big Losses)
- 19. Autonomous Maintenance I run it, you fix it I fix it, you run it
Editor's Notes
- The first 8 steps are part of our preparation, and you can plan on spending 3 to six months on this stage depending on the size of your company. Step 1 Top management Commits to Implement TPM: The success or failure of TPM greatly depends on the determination and enthusiasm of top management. The top person should personally declare the determination to implement TPM at a staff meeting and that declaration should be printed in a company bulletin or newsletter Step 2 Introductory education and training: Top executives and management should be educated first so they know what their roles are in TPM. The training should then be cascaded down to the rest of the employees. Step 3 Establish TPM promotional organization: TPM is promoted through overlapping small group activities. A TPM promotion office should be established and staffed with full time person’s to promote TPM. Step 4 Value stream map and select pilot model: A value stream map of the area that you intend on first introducing TPM too should be conducted and machine’s prioritized. You should then select your pilot model it is recommended that you do not select the most critical bottleneck as your pilot model machine. You want to make sure you pick a winnable pilot. Step 5 Collect OEE data and Baseline: If OEE data is not available for your pilot model then 2-3 months of OEE data should be collected. This holds true for reliability data as well. This is also the time that you should get the finance department involved to help track costs and benefits of TPM. Step 6 Set basic Policies and targets: Implementing TPM is not a goal in itself. TPM is executed as a means of attaining corporate needs, principles and targets. This should always be kept in mind when setting basic principles and target of TPM. Step 7 Create Master Plan for TPM implementation: The master plan specifies the details of the principle TPM activities and gives start and completion dates for implementation of each of the pillar activities Step 8 TPM Kickoff: TPM kickoff can be as simple as letter from the top executive kicking off the TPM program or as elaborate as a large scale event where all employees are invited to a formal TPM kickoff ceremony.
- Steps 9- 14 are the actual implementation of TPM, and begin immediately following the kickoff. It generally takes 2 1/2 to 3 years to reach world class levels. However Larger businesses with many employees may require 3 to 5 years
- Ask for examples of each of these losses. Which loss is usually the biggest? (Setup is typically the biggest loss.) Many AIW activities are strictly focused on setup reduction with the goal being less than 10 minutes. An example is of a machine setup improvement within Boeing where the setup was reduced from over 4 hours to 3 seconds. Key Points: What gets measured gets done. Let’s make what’s important more measurable, Instead of what’s measurable more important!!!
- The way things usually are today. This can apply to almost any department, take engineering and Maintenance for instance. Instead of I run it you fix it. It would be I design it, you fix and vise versa.