This document outlines an agenda for implementing Total Productive Maintenance (TPM) at Avery Dennison's offset printing facility in Bangladesh. It discusses what TPM is, its history and pillars. It performs a SWOT analysis and identifies limitations. It selects key losses to focus on using Pareto analysis and outlines key performance indicators. It describes developing a project plan, establishing baselines and targets, and creating a yearly TPM calendar. It discusses autonomous maintenance checklists, training metrics, setup time reduction and presenting results and further action plans.

1. 9/25/2011
Avery Dennison
Offset TPM Implementation : Bangladesh
> Iftekhar Aziz & Naynendu Bagchi
RBIS
AP / Bangladesh
14 July 2011
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Agenda
What is TPM??
History of TPM.
16 Major losses.
TPM 8 Pillars.
SWOT Analysis.
Limitations of our implementation.
Initiate implementation : Department & Losses Selection #Pareto analysis.
What are the KPIs??
How we start the journey.
Develop Project A3.
Base Line & Target Condition.
Yearly TPM calendar preparation.
PM1: Autonomous Maintenance checklist & tracking system for PM1.
Training and skill metrics development.
Setup time reduction help from setup time team.
Results.
Further action plans.
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What is TPM??
T: Total TPM
P: Productive
M: Maintenance & Management
Total Productive Maintenance & Management
combines the best features of productive &
preventive maintenance with innovative management
strategies and total employee involvement.
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History of TPM.
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16 Major losses.
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TPM 8 Pillars.
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SWOT Analysis
Strengths Weakness
Management’s focus on TPM. Operators’ mind setup.
Platform team’s support. Not having enough technical people.
Skilled manpower. Not having frequent audit system.
Department’s willingness for TPM. Unwillingness for Tags fill up.
Opportunities Threats
Different m/c category. Peak season higher order volume.
Complex equipment parts. Procurement policies.
Discussion on MDI. Root cause analysis of the Tags.
Publishing success story. Regular follow up of PM1.
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Limitations of our implementation.
Implement TPM initially in the Offset.
Focusing on the Breakdown time loss only.
Implement TPM for the major machines.
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Initiate implementation : Department & Loss Selection #Pareto analysis
Loss Selection
Shut down loss: Power failure.
Management loss: Training/Meeting, waiting for instruction, waiting
for proof reading, no work.
Operating motion loss: Job changing.
Schedule down time loss: Day end cleaning.
Logistics loss: Waiting for material, ink preparation
Break down loss: Machine break down.
Measurement/Adjustment loss: Trouble shooting.
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Initiate implementation : Department & Loss Selection #Pareto analysis
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What are the KPIs??
Trained Multi Skill
Operators #
Uptime
Setup Time UEE
Scrap
Maintainability
MTTR
Uptime
MTBF Performance
Availability
UEE
Breakdown Time Uptime
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How we start the journey
Initiate
Implementation
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Develop Project A3
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Base Line & Target Condition
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Yearly TPM calendar preparation
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TPM Completion
laireS oN C/M emaN C/M sutatS MPT
1 10 L C4 OTG
2 20 L C4 OTG
3 30 L C2 OTG
4 40 L C2OTG
5 50 L C1-64-MQ Total No of m/c : 14
6 32 L C2 OTG
7 42 L DROK
8 52 L C1 OTG
TPM initiates taken : 13
9 92 L 47 DC
01 13 L C2 OTG TPM initiates missing : 1
11 84 L C4 OTG
21 47 DC DA 47 DC DA
31 25 MS 25 MS
41 ZOM ZOM
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PM1: Autonomous Maintenance checklist & tracking system for PM1.
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Training and skill metrics development.
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Setup time reduction help from setup time team.
∏ Find out the base line
∏ Set the targeted time
∏ SOP from P & C
∏ SMED training for operators
∏ Explain SOP
∏ Implement SOP in local language
∏ Continuously monitor setup time
∏ Watch other site’s setup time
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Action Figures
TPM Kick Off
Declaration
from Top
Management
TPM
Introduction
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Action Figures
Initial briefing
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Action Figures
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Action Figures
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Action Figures
Before
Dust, Grease & Ink are everywhere which stuck into the m / c parts
After
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Action Figures
Before
After
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Action Figures
Before
After
Cleaning is not easy as it sounds
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After Cleaning
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Brain storming
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Training
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Results
Breakdown Time
MTBF & MTTR Setup Time
Base Line:
Unplanned Downtime, Trained operator #
mins/week: 5396
Current Condition:
TPM trained operators: 0
Unplanned Downtime,
Target Condition:
MTBF, hr/week: 36.6 mins/week: 2738
Unplanned Downtime,
TPM trained operators: 50
MTTR, hr/week: 4.13 mins/week: 4047
MTBF, hr/week: 29.35
Setup Time, mins: 58 TPM trained operators: 100
MTTR, hr/week: 3.1
MTBF, hr/week: 40
Setup Time, mins: 39
MTTR, hr/week: 3.5
Setup Time, mins: 30
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Schedule & Unscheduled Breakdown time contrast
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Unscheduled Breakdown time contrast
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MTBF (Mean Time between Failure) contrast
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MTTR (Mean Time to Repair) contrast
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Setup Time : Actual Vs Target
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Fuguai Tags
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Further action plans.
Initial cleaning schedule for Varimatrics, Die- cut,
Guillotine
PM 1 for SM 52, MOZ
PM 2 for GTO, CD 74
Maintenance checklist training for SM 52, MOZ
Spare parts management system
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