The document provides an overview and introduction to Total Productive Maintenance (TPM). It discusses why TPM is important for achieving goals like zero defects and breakdowns. TPM aims to prevent equipment deterioration through techniques like autonomous maintenance, planned maintenance, and quality maintenance. It outlines the seven steps of autonomous maintenance and explains how TPM is implemented through its various pillars in a strategic phased approach beginning with establishing maintenance standards.
Total Quality Managment - TPM - final year B.E.cs - Presented by DR. K. BARANIDHARAN, SAIRAM INSTITUTE OF MANAGMENT STUDIES (sims) SRI SAI RAM INSTITUTE OF TECHNILIGY (sit) CHENNAI
TPM Total Productive Maintenance for Quarry Plant(2) Timothy Wooi
This is the day 2 Course for TPM which is a company wide team-based effort to build quality into equipment and to improve overall equipment effectiveness (OEE) towards Zero Breakdown.
It covers Steps in Introduction of TPM, The 5’S Step towards TPM, Conditions Required for TPM, TPM Strategy
TPM Tools, Set-back of TPM Implementation, Course Evaluation, Recap and Closing
TPM is a Japanese concept evolved in 1951. TPM is a robust method of effective machine repairing, maintenance and an organized systematic initiative to increase machine life.
TPM has been recognized widely and accepted by many organizations as a management philosophy for effective asset management.
To improve equipment effectiveness.
To improve efficiency, effectiveness and reliability of maintenance of machines.
To train the staff in relevant maintenance skills.
To achieve early equipment management.
The presentation gives a brief explanation about the 8 pillar of TPM.It is medical science of machines.TPM focuses on maintenance as a necessary and vitally important part of the business. It is no longer regarded as a non-profit activity. The goal is to hold emergency and unscheduled maintenance to a minimum.
It is a holistic approach towards equipment maintenance where the aim is to achieve the best possible productivity with no breakdowns, no unplanned failures, no stops, no defects and no accidents.
TPM the effective maintenance with Autonomous MaintenanceTimothy Wooi
This is a 2 days course on Total Productive Maintenance (TPM) that will guide you through to implement Autonomous Maintenance (AM) on your current Equipment and to plan the execution of your Preventive (PM) & Predictive Maintenance (PdM).TPM defines your Maintenance schedule and Goals. TPM helps you plan and develop the optimal program for your facility, resulting in increased efficiency and cost savings.
Day 1
TPM General Overview with Autonomous
Maintenance (AM) as the back bone of TPM
6 Steps to Autonomous Maintenance
Audit , Review & Externalize Inspection Activities
from Equipment Manual to (AM)
Executing Equipment Audit to start (AM) & (PM)
-TPM Board & AM Checklist with Visual
Management Implementation.
It is Japanese Approach for
Creating company culture for maximum efficiency
Striving to prevent losses with minimum cost
– Zero breakdowns and failures, Zero accident, and Zero defects etc.
The essence of team work (small group activity) focused on condition and performance of facilities to achieve zero loss for improvement
Involvement of all people from top management to operator
My Home page is Japanese Gemba Kaizen Web
http://takuminotie.com/english/
Please Look and Like us on Facebook
Table of contents
1. TPM Concept
2. TPM Definition
3. TPM Philosophy
4. TPM Essence
5. Improvement lead to real benefits
6 .Case of small amount of work
7.TPM organization
8. TPM History
9.TQC&TPM
10. Step 12 of the TPM program
11.8 main pillars of TPM
12. Participation of all employees activities
13. TPM Promotion Organization
14. Case of TPM promotion organizations
15. TPM basic policy and Goal
16. Ask the machine
[Note: To download the complete presentation, visit:
https://www.oeconsulting.com.sg/training-presentations]
Total Productive Maintenance (TPM) is a comprehensive approach to equipment maintenance that aims to optimize equipment efficiency, reliability, and performance. It involves a holistic approach to maintenance, encompassing both the technical and the human aspects of equipment management. TPM is often associated with Lean Manufacturing, which emphasizes the elimination of waste and continuous improvement.
The primary objective of TPM is to improve equipment effectiveness by minimizing downtime, reducing defects, and increasing overall equipment efficiency. This is achieved through the implementation of a set of maintenance strategies that involve both the equipment operators and maintenance staff. TPM has several benefits, including increased productivity, reduced downtime, improved quality, increased safety, and improved morale among employees.
Our TPM presentation is created by a certified JIPM TPM consultant and delivers a comprehensive training experience. Covering the TPM tools, 5S, OEE (Overall Equipment Effectiveness), and the eight pillars with a focus on Autonomous and Planned Maintenance, this detailed presentation outlines the step-by-step process for TPM implementation. By incorporating practical examples and real-world applications, this presentation provides an engaging and effective way to introduce and implement TPM in your organization.
LEARNING OBJECTIVES
1. Understand the concept and management philosophy of TPM as a foundation for Lean Transformation
2. Learn the 8 pillars of TPM activities, TPM implementation strategy, roadmap and step-by-step approach
3. Learn the TPM tools and be able to identify and eliminate loss through TPM implementation
4. Learn how to kick-start TPM deployment with the key pillars such as Autonomous Maintenance, Planned Maintenance, Focused Improvement and Education & Training activities to improve equipment reliability
5. Understand the roles of a TPM implementation organization and the critical success factors
Total Quality Managment - TPM - final year B.E.cs - Presented by DR. K. BARANIDHARAN, SAIRAM INSTITUTE OF MANAGMENT STUDIES (sims) SRI SAI RAM INSTITUTE OF TECHNILIGY (sit) CHENNAI
TPM Total Productive Maintenance for Quarry Plant(2) Timothy Wooi
This is the day 2 Course for TPM which is a company wide team-based effort to build quality into equipment and to improve overall equipment effectiveness (OEE) towards Zero Breakdown.
It covers Steps in Introduction of TPM, The 5’S Step towards TPM, Conditions Required for TPM, TPM Strategy
TPM Tools, Set-back of TPM Implementation, Course Evaluation, Recap and Closing
TPM is a Japanese concept evolved in 1951. TPM is a robust method of effective machine repairing, maintenance and an organized systematic initiative to increase machine life.
TPM has been recognized widely and accepted by many organizations as a management philosophy for effective asset management.
To improve equipment effectiveness.
To improve efficiency, effectiveness and reliability of maintenance of machines.
To train the staff in relevant maintenance skills.
To achieve early equipment management.
The presentation gives a brief explanation about the 8 pillar of TPM.It is medical science of machines.TPM focuses on maintenance as a necessary and vitally important part of the business. It is no longer regarded as a non-profit activity. The goal is to hold emergency and unscheduled maintenance to a minimum.
It is a holistic approach towards equipment maintenance where the aim is to achieve the best possible productivity with no breakdowns, no unplanned failures, no stops, no defects and no accidents.
TPM the effective maintenance with Autonomous MaintenanceTimothy Wooi
This is a 2 days course on Total Productive Maintenance (TPM) that will guide you through to implement Autonomous Maintenance (AM) on your current Equipment and to plan the execution of your Preventive (PM) & Predictive Maintenance (PdM).TPM defines your Maintenance schedule and Goals. TPM helps you plan and develop the optimal program for your facility, resulting in increased efficiency and cost savings.
Day 1
TPM General Overview with Autonomous
Maintenance (AM) as the back bone of TPM
6 Steps to Autonomous Maintenance
Audit , Review & Externalize Inspection Activities
from Equipment Manual to (AM)
Executing Equipment Audit to start (AM) & (PM)
-TPM Board & AM Checklist with Visual
Management Implementation.
It is Japanese Approach for
Creating company culture for maximum efficiency
Striving to prevent losses with minimum cost
– Zero breakdowns and failures, Zero accident, and Zero defects etc.
The essence of team work (small group activity) focused on condition and performance of facilities to achieve zero loss for improvement
Involvement of all people from top management to operator
My Home page is Japanese Gemba Kaizen Web
http://takuminotie.com/english/
Please Look and Like us on Facebook
Table of contents
1. TPM Concept
2. TPM Definition
3. TPM Philosophy
4. TPM Essence
5. Improvement lead to real benefits
6 .Case of small amount of work
7.TPM organization
8. TPM History
9.TQC&TPM
10. Step 12 of the TPM program
11.8 main pillars of TPM
12. Participation of all employees activities
13. TPM Promotion Organization
14. Case of TPM promotion organizations
15. TPM basic policy and Goal
16. Ask the machine
[Note: To download the complete presentation, visit:
https://www.oeconsulting.com.sg/training-presentations]
Total Productive Maintenance (TPM) is a comprehensive approach to equipment maintenance that aims to optimize equipment efficiency, reliability, and performance. It involves a holistic approach to maintenance, encompassing both the technical and the human aspects of equipment management. TPM is often associated with Lean Manufacturing, which emphasizes the elimination of waste and continuous improvement.
The primary objective of TPM is to improve equipment effectiveness by minimizing downtime, reducing defects, and increasing overall equipment efficiency. This is achieved through the implementation of a set of maintenance strategies that involve both the equipment operators and maintenance staff. TPM has several benefits, including increased productivity, reduced downtime, improved quality, increased safety, and improved morale among employees.
Our TPM presentation is created by a certified JIPM TPM consultant and delivers a comprehensive training experience. Covering the TPM tools, 5S, OEE (Overall Equipment Effectiveness), and the eight pillars with a focus on Autonomous and Planned Maintenance, this detailed presentation outlines the step-by-step process for TPM implementation. By incorporating practical examples and real-world applications, this presentation provides an engaging and effective way to introduce and implement TPM in your organization.
LEARNING OBJECTIVES
1. Understand the concept and management philosophy of TPM as a foundation for Lean Transformation
2. Learn the 8 pillars of TPM activities, TPM implementation strategy, roadmap and step-by-step approach
3. Learn the TPM tools and be able to identify and eliminate loss through TPM implementation
4. Learn how to kick-start TPM deployment with the key pillars such as Autonomous Maintenance, Planned Maintenance, Focused Improvement and Education & Training activities to improve equipment reliability
5. Understand the roles of a TPM implementation organization and the critical success factors
Total Productive Maintenance (TPM) for EVERTS 20Aug2018Timothy Wooi
This is a 2 day Course which is a company wide, team-based effort, to build quality into equipment, and to improve overall equipment effectiveness (OEE) towards Zero Breakdown.
It uses Total Quality Control and Total Employee Involvement approach, in maintaining the Equipment towards a “ready to use condition” using energy efficiently.
This course will guide you through to assess the activities of Autonomous Maintenance (AM) on your current Equipment and to plan the execution of your Maintenance Activities using a Visual Schedule.
TPM defines your Maintenance schedule and Goals..
TPM helps you plan and develop the optimal program for your facility, resulting in increased efficiencies and cost savings
Significance of Preventive Maintenance Automation in the Post Corona Era | In...Srinivasan AT
As a maintenance manager or an office-bearer do you come up on any of the below issues or shortcomings?
Measuring the performance of service technicians & reporting mechanism is difficult.
Unexpected failure of critical equipments spoils the integrity of entire production line.
Unfamiliarity with automation of preventive maintenance and not sure if it will be worth the deal.
I've used a CMMS but it hardly offered us any significant benefits.
The traditional approach based on paper work or excel spreadsheets is tedious.
Long waiting time for supervisor approval of scheduled PPM Task.
This webinar is a gateway to learn the significance of preventive maintenance and its automation and relate how this will contribute to the sustenance and progress of your business.
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Putting the SPARK into Virtual Training.pptxCynthia Clay
This 60-minute webinar, sponsored by Adobe, was delivered for the Training Mag Network. It explored the five elements of SPARK: Storytelling, Purpose, Action, Relationships, and Kudos. Knowing how to tell a well-structured story is key to building long-term memory. Stating a clear purpose that doesn't take away from the discovery learning process is critical. Ensuring that people move from theory to practical application is imperative. Creating strong social learning is the key to commitment and engagement. Validating and affirming participants' comments is the way to create a positive learning environment.
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RMD24 | Debunking the non-endemic revenue myth Marvin Vacquier Droop | First ...BBPMedia1
Marvin neemt je in deze presentatie mee in de voordelen van non-endemic advertising op retail media netwerken. Hij brengt ook de uitdagingen in beeld die de markt op dit moment heeft op het gebied van retail media voor niet-leveranciers.
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Grote partijen zijn al een tijdje onderweg met retail media. Ondertussen worden in dit domein ook de kansen zichtbaar voor andere spelers in de markt. Maar met die kansen ontstaan ook vragen: Zelf retail media worden of erop adverteren? In welke fase van de funnel past het en hoe integreer je het in een mediaplan? Wat is nu precies het verschil met marketplaces en Programmatic ads? In dit half uur beslechten we de dilemma's en krijg je antwoorden op wanneer het voor jou tijd is om de volgende stap te zetten.
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Memorandum Of Association Constitution of Company.pptseri bangash
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A Memorandum of Association (MOA) is a legal document that outlines the fundamental principles and objectives upon which a company operates. It serves as the company's charter or constitution and defines the scope of its activities. Here's a detailed note on the MOA:
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https://seribangash.com/article-of-association-is-legal-doc-of-company/
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A personal brand exploration presentation summarizes an individual's unique qualities and goals, covering strengths, values, passions, and target audience. It helps individuals understand what makes them stand out, their desired image, and how they aim to achieve it.
1. TPM Exec Briefing Presented By ZenPower Int'l @
www.tpmquality.com
1
Executive TPM Introduction
& Overview
1. Why Is TPM Important and Relevant?
2. How and Why TPM Works?
3. How To Implement TPM Effectively And
Quickly And Achieve Bottom-line ROI?
4. Q & A
2. TPM Exec Briefing Presented By ZenPower Int'l @
www.tpmquality.com
2
Welcome !!
Executive TPM Briefing Notes
MOSES TAN (MSc; BIT)
Principal LEAN/TPM Consultant
ZenPower International
10 Anson Rd, #16-16; International
Plaza, Republic of Singapore
Mobile: +65.97273525
Fax: +65.64545402
Emails: zentan@singnet.com.sg
mosestc@gmail.com
LEAN MANAGEMENT SOLUTIONS
www.tpmquality.com
- LEAN ScoreBoard® Software
Solution for LEAN Manufacturers
- FastTrack TPM Implementation
- eBooks On TPM, Poka Yoke, 5S
Singapore - Malaysia
India - China
Contact Us For A No-Obligations Top Management Briefing.
3. TPM Exec Briefing Presented By ZenPower Int'l @
www.tpmquality.com
3
Moses Tan is the Principal consultant of ZenPower International, an experienced TPM expert since 1996. He greatly
emphasizes on implementation details and methods. With an extended 20 years of experience, Moses was previously a
TPM Training Manager with a Japanese-owned semiconductor manufacturer, Silicon Systems, a wholly-owned
subsidiary of TDK Corporation, Japan. TDK is an advanced TPM Practitioner and a recipient of the prestigious World-
Class TPM award from the JIPM.
As TPM manager, he led in hands-on TPM Implementation and conducted TPM Training, 5S, Kai’zen employee
suggestion system and other TPM-related technical skills training. His large clientele includes NEC electronics, Carsem
Semiconductor, Hitachi, SCI Manufacturing, NEC Seminconductor, Siemens, Sony Display Devices, Sumitomo
bakelite, Infineon, Malaysian Newsprint Industries, Yamaha Motors, Hong Leong, Hitachi-Nippon Steel, Taiko
Electronics, Showa Denki, Guocera Tiles Industries and the list goes on (see next page)
He has consulted for both the discrete and process industries and consistently improved their ROI. His focus of
expertise includes all the TPM Pillars – Autonomous Maintenance, Planned maintenance, Focused Improvements,
Quality Maintenance, Poka Yoke, Office, Administrative and Warehouse TPM, 5S, Kai’zen Suggestion System, Why-
Why Analysis and P-M Analysis with Design of Experiments. He also successfully prepared a major Client for the JIPM
PM Award and has conducted numerous public and in-house seminars which were always graded extremely well. He is
also the Inventor of the LEAN ScoreBoard™ which enables any Manufacturer to convert his Process/machine indices
in LEAN, TPM, 6-Sigma Programs to be quantified into COSTs and vice-versa.
He occasionally contributes TPM articles to the Productivity and Services Board, Singapore. He has also received
professional recognitions through awards like the 1989 National Training Awards for the Manufacturing Sector,
Singapore; the 1992 & 1994 National Training Commendation Awards, Singapore; 1995 Essay Prize from the Singapore
Quality Association for his published article on “TQM Implementation In Singapore MNCs”.
Moses holds a Diploma in Education (Technical); a Diploma in Electronics Engineering from the Singapore Polytechnic;
a Bachelor’s in Information Technology from University of southern Queensland; and a MSc In Training (major in
TQM) from the University of Leicester, UK.
A Word About Moses…..
4. TPM Exec Briefing Presented By ZenPower Int'l @
www.tpmquality.com
4
OUR GROWING LIST OF TPM CLIENTS WHO HAD ENGAGED OUR PROFESSIONAL
CONSULTING, IN-HOUSE AND PUBLIC TRAINING SERVICES – 1996 TO 2006
CARSEM SEMICONDUTOR SDN BHD; CARSEM SEMICONDUCTOR MALAYSI SDN BHD; SCI
MANUFACTURING SINGAPORE PTE LTD; SINGAPORE MITSUBISHI BELTING PTE LTD; NEC
SEMICONDUTOR PTE LTD; DISPLAY DEVICE (Spore) PTE LTD; .SHOWA DENKO HD; SUMITOMO
BAKELITE PTE LTD SINGAPORE, SIEMENS COMPONENTS PTE LTD; MALAYSIA NEWSPRINT
INDUSTRIES SDN BHD; GUOCERA TILES INDUSTRIES (Kluang) SDN BHD; YAMAHA MOTORS HONG
LEONG SDN BHD; HITACHI-NIPPON STEEL PTE LTD SINGAPORE; TAIKO DENKI SDN BHD, SENAI;
MALAYSIA NEWSPRINT SDN BHD; TATA MOTORS LIMITED; BHARAT HEAVY ELECTRICALS LIMITED;
INDIAN OIL CORPORATION LIMITED; HMT MACHINE TOOLS LIMITED; HEG LIMITED; ITC LIMITED;
MOSER BAER INDIA LTD; NTPC LIMITED; NORTH DELHI POWER LIMITED; THE TATA IRON AND STEEL
COMPANY LIMITED; TRIDENT AUTO COMPONENTS PVT LTD; HALLA CLIMATE CONTROL (THAILAND)
CO LTD;KIRLOSKAR FERROUS INDUSTRIES LIMITED; TIMKEN INDIA LIMITED; SULZER INDIA LIMITED;
KIRLOSKAR COPELAND LIMITED; CAPTIVE POWER PLANT; ALLIED NIPPON LIMITED; UNICHEM
LABORATORIES LTD; NATIONAL ALUMINIUM COMPANY LTD; KIRLOSKAR BROTHERS LIMITED;
SANDVIK ASIA LTD; TATA CHEMICALS LTD; NALCO; TATA POWER LTD; DR REDDY’S LABS, BALDA
THONG-FOOK SOLUTIONS, SIAM-CEMENT; SANDVIK ASIA; UNICHEM;SAMSUMG
ELECTRONICS;BHARAT HEAVY ELECTRICAL LTDNATIONAL ALUMINIUMS COMPANY LTD; KIRLOSKAR
BROTHERS LTD; MOSER BAER INDIA LTD;INDIAN OIL CORPORATION LTD; HTM MACHINE TOOLS LTD;
HEG LIMITED;ITC LIMITED;NTPC LIMITED; NORTH DELHI POWER LIMITED; TATA IRON AND STEEL
COMPANY LTDTRIDENT AUTO COMPONENETS PVT LTD;KIRLOSKAR FERROUS INDUSTRIES LIMITED;
SULZER INDIA LTD;KIRLOSKAR COPELAND LIMITED.
*References can be supplied upon request.
5. TPM Exec Briefing Presented By ZenPower Int'l @
www.tpmquality.com
5
Background Of TPM
• Championed by the JIPM organization in Japan.
• Mandatory participation – Corporate Policy.
• T = Total, P = Productive, M = Maintenance.
• T = Total, P = Production, M = Management.
• T = Total, P = Perfect, M = Management.
• Evolved in Japan since 70s from Toyota for Companies
who desperately want to WIN in today’s competition.
6. TPM Exec Briefing Presented By ZenPower Int'l @
www.tpmquality.com
6
1.Why Is TPM Important and
Relevant?
a. Emphasizes Equipment Excellence as backbone of
Manufacturing Excellence.
b. Integrates Whole Factory’s Improvement Program
into ONE.
c. Major Improvement Systems, Measurements &
Tools to achieve Zero Defects, Zero Breakdowns,
Delivery and Cost-Down Goals.
7. TPM Exec Briefing Presented By ZenPower Int'l @
www.tpmquality.com
7
TPM Focus On Equipment:
• Every breakdown and defect is due to a deviation
…from the required Basic Machine Conditions.
• Adhering To The Basic Machine Conditions keeps
…Manufacturing Equipment From Breaking Down or
…Generating Defects.
• The Basic Conditions Are: 1) Cleaning
…2) Lubrication, 3) Bolt-Retightening. These are
…enforced with Equipment Inspection & Precision
…Checks by Operators, Prod Techs and Maint. Techs.
8. TPM Exec Briefing Presented By ZenPower Int'l @
www.tpmquality.com
8
Concept of Forced Deterioration
• Equipment deterioration is natural. But neglect cause a
…much faster and greater amount of deterioration resulting in
…expensive breakdowns and defects.
• Main culprits are faulty lubrication, dust, dirt, loose
…parts, missing, loose or over-tightened bolts and nuts,
…mis-operation, faulty repairs.
• TPM aims to achieve Prevention, Early Detection and
…Restoration of deterioration.
9. TPM Exec Briefing Presented By ZenPower Int'l @
www.tpmquality.com
9
TPM Unites Whole Company In Single Program
Autonomous
Maintenance
Equipment
Improvement
Planned
Maintenance
Quality
Maintenance
5S – Admin
&
Warehouse
TPM
Safety –
Environment,
sanitation
and hygiene
Major Pillars in TPM Implementation.
Production
Operators
Other
Manufacturing
Personnel
Maintenance,
Equipment,
Process & QA
Engineers and
workers, R&D
Administrative Personnel
Document Control, Production Planning,
Warehouse, Shipping, HR&D, Security,
Finance, Purchasing, Stores, Safety, and any
general offices or administrative departments.
Training
10. TPM Exec Briefing Presented By ZenPower Int'l @
www.tpmquality.com
10
Total Involvement Needed: Eg: When A Production
Machine Breaks down, various losses are incurred such
as:
1. Time taken to report the breakdown.
2. Time taken to locate the technician.
3. Time taken to verify the breakdown.
4. Time to get tools.
5. Time to get spare parts.
6. Actual Time to repair the machine.
7. Time to buyoff the machine after repair.
Except for #6, the
other losses are
management or
administrative or
supervisory
related losses.
11. TPM Exec Briefing Presented By ZenPower Int'l @
www.tpmquality.com
11
The Pillars of JIPM-TPM Are:
Each Pillar represents one activity-type of TPM focus.
1. Equipment-Improvement Pillar.
2. Production Autonomous Maintenance Pillar.
3. Planned Maintenance Pillar.
4. Education & Training Pillar.
5. Initial New Equipment & Products Control Pillar (MP)
6. Quality Maintenance Pillar.
7. Warehouse & Administrative TPM Pillar.
8. Safety, Hygiene & Work Environment Pillar.
Two other important activities deserve to be emphasized here:
9. Target setting and Measurement
10. TPM Section/Department. Source: JIPM
12. TPM Exec Briefing Presented By ZenPower Int'l @
www.tpmquality.com
12
2. How & Why TPM Works?
a. Overall Design Logic Of TPM.
b. 7 Steps and 4 Stages Of Autonomous Maintenance.
c. The Initial Stage Of TPM Sustainability.
d. Developing Advanced Stages of TPM.
• Focused Equipment Improvement
• Quality Maintenance & Poka Yoke
• Chronic Defects
• Self Managing Work Teams
13. TPM Exec Briefing Presented By ZenPower Int'l @
www.tpmquality.com
13
PM
EI
AM
QM
5S
Others
Overall Design Logic / Relationship
Between TPM Pillars
CORE Pillars Are
• Autonomous
..Maintenance
• Planned
..Maintenance
14. TPM Exec Briefing Presented By ZenPower Int'l @
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14
Design of Autonomous Maintenance.
(Approach to changing worker mindset, Improve Worker-Skills & workplace culture)
Step 0
Step 1
Step 2
Step 3
Step 4 Step 5 Step 6 Step 7
Motivation Improve the Equipment Improve the Operators Improve
Eyes-opened. Organization. Culture.
Sustainable Foundational
Phase is at AM Step 4
Advanced AM Steps 5,6,7 heavily
rely on Planned Maintenance, EI,
QM, Solving Chronic Problems.
15. TPM Exec Briefing Presented By ZenPower Int'l @
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15
We Take A Very Quick Look At
CORE PILLAR - Autonomous
Maintenance.
• They Are Structured.
• They Are Sequentially Implemented
• They Are Led By Production Supervisors
But Technically Supported By Maintenance
Group.
17. TPM Exec Briefing Presented By ZenPower Int'l @
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( Step( Step--1 : Restoration Equipment )1 : Restoration Equipment )
OPERATORS
LEADER
MAINT.
STAFF
ENGR.
STAFF
CONFIRMATION
OF PROGRESSDEPT.CHIEF
SUPERVISORS
GROUP LEADER
LIST OF EXT/INT
ABNORMALITIES
MEETING TO
PLAN COUNTER
MEASURES
COUNTER
MEASURES
STEP-1 AUDIT
MODEL MACHINE
MAINTENANCE
STAFF
ENGINEERING
STAFF
AUTONOMOUS
MAINTENANCE
GROUP
FOLLOW UP ON AUDIT
FEEDBACK
COUNTERMEASURES
EXTENDED TO ALL
EQUIPMENT
AUDIT
DEPT.CHIEF
LEADER
SUPERVISORS
TO NEXT STEP
18. TPM Exec Briefing Presented By ZenPower Int'l @
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( Step( Step--2 : Eliminate Contamination & Stains on Area & Parts)2 : Eliminate Contamination & Stains on Area & Parts)
Complete Step-1
Step-1 Summary
results & findings
What ?
Where ?
How
much
Why ?
AM Team
=> 70%
Countermeasures
1st Pre-
Audit
by TPM
Dept.
Present
Countermeasures
to TPM WC and
implementation
GM/Sponsors
Audit
Step-3
Own area
Buy - Off
19. TPM Exec Briefing Presented By ZenPower Int'l @
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( STEP 3 : IMPROVE EQUIPMENT ACCESSIBILITY ).
AM Leader
Model m/c
Passed
Step 2
Areas difficult or
inaccessible for cleaning
checking & lubricating
Inaccessible
No Place To
Stand
Wiring or piping
obstruct
Cannot see
easily
Time Consuming
to clean
Time Consuming
to clean
Product Manager
Operator Leader/ Operators
Supervisor
Model Machine
Goes To
Step 4
Pre-Audit
by TPM Dept.
W/C
Buy Off
GM
Audit
Own
Area
Buy Off
20. TPM Exec Briefing Presented By ZenPower Int'l @
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( Step 4 : Initial Maintenance Standards )( Step 4 : Initial Maintenance Standards )
Model m/c
passed
Step 3
Initial
maintenance
standard
Hard to
lubricate
Hard to check
oil level
Abnormality
in lubrication
equipment
Abnormality
in circulation
of lubrication
Equipment
gets dirty
during oiling
Product Manager
AM Leader
Operator
Leader/operator
Counter measure for
cleaning and checking
Supervisor
Draft standards
for cleaning,
inspection &
lubrication
Engineer & Maintenance
Trial Period
Attach
identification
label
Confirm
standard for
cleaning,
inspect &
lubrication
TPM dept.
Pre-audit GM audit
Proliferation
of Step 4
21. TPM Exec Briefing Presented By ZenPower Int'l @
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AM Step 4 Initial Maintenance
Standards
• Equipment
…..Cleaning Standards.
• Equipment
…...Lubrication Standards.
• Equipment Inspection
…...Standards
Information
Collected From:
• AM Steps 1-3
• Lubrication Study
...Program.
• Bolt-tightening Study
...Program
• Why-Why Analysis of
...Equipment Sporadic
...Breakdowns.
22. TPM Exec Briefing Presented By ZenPower Int'l @
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A Strategic Implementation Plan Sees
AM Steps 0-4 As A Single Stage.
Step 0
Step 1
Step 2
Step 3
Step 4 Step 5 Step 6 Step 7
Sustainable Foundational
Phase is at AM Step 4
• Resource Allocation.
• Implementation Strategies & focus.
• Delay Advanced Planned Maint., EI, QM till Foundation
…….is laid.
23. TPM Exec Briefing Presented By ZenPower Int'l @
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Prepare texts and daily
schedules/check lists
Prepare texts and daily
schedules/check lists
( Step 5 : General Inspection skills )( Step 5 : General Inspection skills )
•Lubrication
•Equipment parts tightening
•Pneumatics
•Hydraulics
•Electrical
•Drive System
•Water
•Fire prevention/safety
•Lubrication
•Equipment parts tightening
•Pneumatics
•Hydraulics
•Electrical
•Drive System
•Water
•Fire prevention/safety
select general
inspection items
select general
inspection items
ManualsManualsManuals
ChecklistChecklist
Cut away
models
Cut awayCut away
modelsmodels
Revised
Maintenance
standards
RevisedRevised
MaintenanceMaintenance
standardsstandards
Managers/supervisors
participate in training
Managers/supervisors
participate in training
TestTest
Implement
general Im..
TPM office
Pre-Audit
TPM office
Pre-Audit
GM AuditGM Audit
Proliferate
Step-5
24. TPM Exec Briefing Presented By ZenPower Int'l @
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( Step( Step--6 : Autonomous Inspection )6 : Autonomous Inspection )
Maintenance Inspection standards,breakdown analysis
Operators
who
understand
their
equipment
(able
to maintain
inspection
standards)
Step-4Step-4
Daily checking,
adjustment,and
improvement of
conditions for
correct operation
Daily checking,
adjustment,and
improvement of
conditions for
correct operation
Step1 to 3:Step1 to 3:
Establish basic
conditions
(cleaning and
lubrication)
Establish basic
conditions
(cleaning and
lubrication)
Step-5 Revise provisional standards
Finalise standards for cleaning and lubrication
Inspectionskillcheck-up
25. TPM Exec Briefing Presented By ZenPower Int'l @
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StepStep--7 :7 : OrganiseOrganise and Manage Workplaceand Manage Workplace
Organise and set standards for :
EQUIPMENT PRECISION
INSPECTION ITEMS
TOOLS AND MATERIALS
FLOW AND STORAGESTANDARDS FOR
INDIVIDUAL WORK
RESPONSIBILITIES
26. TPM Exec Briefing Presented By ZenPower Int'l @
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After TPM Foundation AM Step 4
Then Other Advanced Pillars
Step 0
Step 1
Step 2
Step 3
Step 4 Step 5 Step 6 Step 7
Build Advanced TPM
Activities Towards Zero
Defects & Zero Breakdowns
27. TPM Exec Briefing Presented By ZenPower Int'l @
www.tpmquality.com
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We Take A Very BRIEF Look At
CORE PILLAR - Planned Maintenance.
• They Are Structured.
• They Accumulates ALL Maintenance Knowledge
…….relating to prevention of breakdowns and defects
…….for both Autonomous Maintenance & Maintenance
…….Department.
• They receive inputs from All Pillars and Problem
…….Solving Teams.
28. TPM Exec Briefing Presented By ZenPower Int'l @
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Developed By: Date: Pg 1/10 Preventive Maintenance Standards
Reviewed By: Date: Machine: Press Legend: * need 1-point lessons
Cleaning Lubrication *Inspection Check
Agent Tool Stds Type Tools Qty Stds See Feel Hear Stds Tool
Drive System
Minor ?? ??
Minor
1) Gravity powder
assembly .
.
Repair
Class-
Minor
/Major
System level
Assy…..
Assy
overall
function
Assy symptoms
(functional +
WIP quality)
*Breakdown parts
of System level
assembly
2.1.1 Setting of Charger and table
plate not level. ..
..
Calibrate every
setup. .
..
TBM change,
calibrate
No lumps
stuck . .
2) Charger assembly
..
. ??
Flat bar .
.
.
…………………
…………………
…………………
…………………
…………………
1.1.1 Mesh, elephant trunk and
powder distributor blocked by
powder lumps.
2.1 Green tiles below
compactness delta range (Q)
. .
1.1 hopper box
powder not full (F)
To feed
powder into
charger grid
To feed
powder into
the mould
cavity and
Building The Maintenance Competence
Standardize future
repairs.
It was a repair error by
Maintenance.
5. Why is the hole there?
Plug the holeUpper plate of tank has a hole.4. Why did dirt get into the
tank?
Prevent surrounding
dirt from scattering.
Dirt has entered the tank.3. Why is the oil dirty?
Drain oil, clean and
replace.
The oil is dirty.2. Why is the oil strainer
clogged?
Clean the strainer.The oil strainer is clogged.1. Why is cylinder operation
jerky?
Actions
(Restorative &
Preventive)
AnswerQuestion
( Hint: Ask questions to point out
Man’s eror)
WHY-WHY Analysis Case 1: Cylinder operation is jerky.
Every problem
solved such as
by Why-Why
Analysis is
“captured” or
“standardized”
permanently.
29. TPM Exec Briefing Presented By ZenPower Int'l @
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PREVENTIVE MAINTENANCE RESPONSIBILITY MASTER LIST
Type of Machine : FUJI PICK AND PLACE Number of Machine : 13
Model of Machine : FCP642E Last Update : 13/02/2001
( Section A ) - Cleaning Checklist
S/N Sub-Assembly Cleaning Item Operator Maint. DM/PM/Prod. Remarks
1 Conveyor cover Top cover O Prod 1 Day
2 XY Table Top Surface O Prod 1 Week
3 Device Table Top Surface O Prod 1 Week
4 M/C Top cover Top cover O Prod 2 Week
5 Servo Control Box Door Panel and Air Filter O Prod 1 Month
6 In and Out Conveyor Railing and Belts O Prod 1 Month
7 Prism Surface Glass surface O PM 3 Month
8 Nozzle Filter Filter Element O PM 3 Month
9 Nozzle Nozzle Tip and Reflecting Sticker O PM 3 Month
10 Filter Regulator Filter Element O PM 3 Month
11 Nozzle Clutch Clutch Surface O PM 3 Month
12 Cam Box All Cam Bearing and Turret O PM 3 Month
Use same format to demark Lub / Inspect / Precision Check / ….
30. TPM Exec Briefing Presented By ZenPower Int'l @
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We Take A Very BRIEF Look At
Equipment Focused Improvement
(Linked Back to Pl. Maintenance)
• From OEE Loss-Chart Analysis, all 16 losses
……known can be measured.
• Each type of Loss such as MTBA, MTBF, Defects,
……Speed losses and Logistics Losses need different
……methodologies.
31. TPM Exec Briefing Presented By ZenPower Int'l @
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Input energy Input materials
(Number, weight)
Effective energy No. of qualified
products
Weight of qualified
products
< Energy > < Materials >
(9) Management
loss
(10) Operating
motions loss
(11) Line organi -
sations loss
(12) Logistics
loss
(13) Measurement and
adjustment loss
(15) Energy loss
(1) Equipment
failure loss
(8) Shutdown loss
(2) Set - up loss
(3) Cutting blade and
jig change loss
(4) Start - up loss
Other downtime
loss
(5) Minor stoppages
& idling loss
(6) Speed loss
(7) Defects and
rework loss
Loss Structure Of Manufacturing Activities (16 Major Losses)
Scheduled downtime
Schedule
downtime
Downtime
loss
Performance
loss
Defects
quality loss
[Manpower Efficiency]
<Manpower> <Equipment>
[Equipment Efficiency]
Excluding manhours
(Supported by other
departments)
Production
manhour
loss
Line organi-
zation
manhour loss
Defects in
manhour loss
5MajorLossesObstructingManpowerEfficiency
Awaiting
instruction loss
Awaiting
material loss
Equipment
downtime loss
Equipment
performance loss
Method/
procedures loss
Skills &
morale loss
Line
organisation loss
Automatization
failure loss
Start-up loss
Overload loss
Temperature loss
Operating Manhours Working hour
Loading manhours Loading time
Net operational
manhours
Operating
time
Effective
manhours
Net operating
time
Valued manhours
(Manhours for
turnout)
Valued
operatingtime
8MajorLossesObstructingEquipmentEfficiency
Cleaning
checking
Awaiting
instruction
Awaiting
materials
Awaiting
personnel
distribution
Quality
confirmation
(Adjustment
of measure-
ment)
Defects quality loss
Start-up loss
Cutting loss
Losses in weight
Losses in overages
(Increased commision)
(14) Yield loss
(16) die, tool & jig loss
EquipmentManpower
Equipment EfficiencyManpower Efficiency
The 6 Big Equipment Losses are (1) Equipment failure or Breakdown Loss (2) Setup Loss (3) Startup Loss(4)
Minor stoppages and Idling Loss (5) Speed Loss and (6) Defect & Rework Loss. The other two (7) Shutdown or
Preventive Maintenance Loss and (8) Cutting Blade and jig change loss may also be considered if significant.
33. TPM Exec Briefing Presented By ZenPower Int'l @
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We Take A Very BRIEF Look At
Quality Maintenance (Poka Yoke)
(Linked Back To Pl. Maintenance)
• Two Major Reasoning Tools: Why-Why Analysis
……and P-M Analysis (with DoE or Taguchi Methods)
• All Breakdowns & Defects have 4Ms Causes BUT
……always started by a Man-Mistake which is the true
……Root Cause.
• Poka Yoke Design starts with Process Defects to
……find Man Mistakes for Mistake Proofing counter-
……measures.
34. TPM Exec Briefing Presented By ZenPower Int'l @
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Checked by Prepared by Phenomenon Physical view (Logical reasoning)
PM Analysis Chart No -/-
Contributing
Condition
Investigation Result
4 M
Correlation,
Investigation Result 4M Correlation,
Second Item Investigation/ Investigation Result If NG, Countermeasure Result
Investigation
Measuring Method
Temporary
Decision
Criterion
Measure -
ment Value
Decision
Investigation/
Measuring Method
Temporary
Decision Criterion
Measure -
ment Value
Decision
(3rd, 4th, 5th and
6th Items
Measuring
Method
Temporary
Decision
Criterion
Measure -
ment Value
Decision
why NG? Restoration, Replace -
ment, Improvement,
Remodeling
Measurement
Value
Decision
1 2
3 4
5 6
0
4 repeat
7 Standardization into
Production System
The Standardized P-M Analysis Worksheet
Note: The 8-steps
sequence are indicated
by the numbers.
Counter measures should
be designed to also address
the Mistake (Man-cause)
using Why-Why Analysis
35. TPM Exec Briefing Presented By ZenPower Int'l @
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P-M ANALYSIS WORKSHOP
2-DAY WORKSHOP + *1-DAY PROJECT-BASED
METHODOLOGY BASED ON JIPM-MODEL
(An Advanced Toyota Production System Problem-Solving Tool)
* Optional, recommended for Project teams
36. TPM Exec Briefing Presented By ZenPower Int'l @
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Man
Method
Machine
M
aterial
MistakesProcess
Prevention
Detection
DEFECTS
Poka-Yoke Design
advanced *3-day workshop
Poka Yoke Design is able to prevent Man’s inadvertent (un-intended) mistakes
in any Process based on the concept that all defects are Man-caused.
ZenPower InternationalZenPower International
Providing Industry Expertise To TrainingProviding Industry Expertise To Training
www.tpmquality.comwww.tpmquality.com
(*3+1 For In-House Training)
37. TPM Exec Briefing Presented By ZenPower Int'l @
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3. How To Do TPM Effectively,
Quickly & Get Bottom-line ROI?
a. A 3½ -Day Management and Leaders’ TPM
Implementation Workshop. (Separate Asia & Europe)
b. Followed by ½ Day TPM Implementation Planning.
c. Use Proven FAST-Track TPM Methodology reaches
AM Step 4 in under 1 ½ years. Results guaranteed.
d. Expert Hand-Holding with various Pillar Leaders.
Individual Site activities + Combined Europe and
Asia + AIM Group Consulting.
40. TPM Exec Briefing Presented By ZenPower Int'l @
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Typical Expected ROI
On Installation Of AM Step 4
Initial Production System
41. TPM Exec Briefing Presented By ZenPower Int'l @
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•• Process Overview.Process Overview.
•• Business results achieved throughBusiness results achieved through
TPM Implementation.TPM Implementation.
Production System through TPM
42. TPM Exec Briefing Presented By ZenPower Int'l @
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Raw Material Batching
Milling
Drying
Pressing
Glazing, Decoration
Firing
Spray Drying
Sorting & Packing
Body mix
Body Slip
Granules
Green tiles
Dry tiles
Fired tiles
Finished goods
Unfired tiles
43. TPM Exec Briefing Presented By ZenPower Int'l @
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Examples Of Common DefectsExamples Of Common Defects
ofof
Ceramic TilesCeramic Tiles
44. TPM Exec Briefing Presented By ZenPower Int'l @
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COMPLAINT ON SIZE VARIATION
45x45cm floor tiles laid with the recommended 4mm gaps but
still show poor uniformity in size. Tile X was found to be 2.5mm
bigger than the rest of the tiles. Therefore, this tile was packed
into the carton by mistake.
X
45. TPM Exec Briefing Presented By ZenPower Int'l @
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MORE EXAMPLES OF WATER SEEPAGE
In this picture, the gel-like substance has penetrate the tile body
through a spot hole on the glaze.
