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Tpm 02
- The document discusses analyzing problems using a "why-why" analysis to find the root 4M (machine, material, method, man) causes by repeatedly asking why. It provides an example PM analysis of a lifting problem. - It discusses key aspects of autonomous maintenance (AM) and planned maintenance for achieving zero failures. Specific implementation activities are outlined. - TPM program success relies on clear top management policy alignment, target management, priority themes, participation incentives, and leadership at all levels. Programs have achieved tangible results like 50% reduced costs and inventory.
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Tpm 02
- 1. • Draw upKaizen sheet and then confirm the result of loss reduction with comparison between before and after kaizen. • Revise Kaizen point of drawing, standard and working procedure • Draw up one point lessons about operator’s skill what was be clear through kaizen activity. • After kaizen activity, it needs to install visual control to necessary point. Productivity Management Office @
- 2. Why – WhyAnalysis • This is an analysis that repeat why about 4M root causes of problem several times. 4M (Machine, Material, Method, Man) • First of all, investigate phenomenon and scene to find out cause of problem and then try to do why-why analysis. • It is useful not only for production field but also different field. • The important point for analysis is to be clear what is problem. • Examine human cause at the end of analysis. Productivity Management Office @
- 3. PM Analysis phenomenon Contributing condition Physicalviewing F3 is not zero 4M cause Vacuum area is small Vacuum power is small F1 is small less than standard Vacuum power is small less than falling power Lift aim can not pick up tray Gap of vacuum position Tray is heavy F2 is heavy more than standard Lifting power is small
- 4. Part 5 ConsultingExperience sharing Productivity Management Office @
- 5. Zero concept andmodel Productivity Management Office @ • Zero model machine • Zero model line • Zero model area Zero machine failure Zero minor stops Zero quality defect Zero cleaning etc.
- 6. Relationship between AMand others Autonomous maintenance 7steps • Step 0 Preparation • Step1 Initial cleaning • Step2 Countermeasures for source of contamination and hard to access. • Step3 Tentative CIL standard • Step4 General inspection • Step5 Autonomous inspection • Step6 Standardization • Step7 Autonomous management
- 7. Planed maintenance forZero failure Planed maintenance 7 Steps Step1 Recognition of current maintenance system Step2 Set up purpose, policy, target. Step3 Organization formation and clarification Step4 Clarification of implementation activities Step5 Study of specific implementation for each activity Step6 Plan farming for implementation with autonomous maintenance Stpep7 Result verification and establishment of maintenance system Productivity Management Office @
- 8. Example of implementationactivities 1. Support activity of Autonomous maintenance 2. Zero failure activity 3. Lubrication management activity 4. Spare parts management activity 5. Maintenance skill up and new technology activity 6. Maintenance cost down activity 7. Maintenance management system activity 8. Maintenance project management activity Visualize maintenance procedure Productivity Management Office @
- 9. Kaizen scenario ofsales growth • Cooperation is significant between sales and manufacturing • Can make but can not sale, can sale but can not make • Which production system is better A or B? • Which product is better for kaizen A or B? Sales Sales P2 P1 a b s 0 1 2 3 4 Productivity Management Office @ Contrary For cost Contrary For profit Opportunity loss Volume Opportunity loss
- 10. Kaizen scenario ofcost down • It should be improved difference of cost and aimed for Real standard cost. • It should be considered ideal standard cost (long term) and real standard cost (short term). Actual cost Productivity Management Office @ Standard cost Present standard cost Real standard cost Ideal standard cost Level3 : Target cost in future Level2n : Target cost after kaizen Target1 : Target cost at present = Actual cost – standard cost Actual loss (difference of cost)
- 11. Loss analysis (Loss tree ) • It makes clear loss structure and plan strategy. Productivity Management Office @ Past loss Forecast loss Past Opportunity loss Opportunity loss Production cost loss Production losses Production cost loss Indirect Production loss Claim loss Stock loss Sales Management loss Past loss
- 12. Management of Kaizentheme • Team leader manages individual kaizen theme and Focused improvement subcommittee manage whole themes by matrix as below. Productivity Management Office @ Large theme Middle theme Small theme Initial Target Actual Parson Date of begin Date of end Achievement Theme 1 Theme1-1 Theme1-1-1 Theme1-1-2 Theme1-2 Theme1-2-1 Theme1-2-2 Theme1-2-3 Theme1-2-4 Theme1-3 Theme1-3-1 Theme1-3-2
- 13. Part 6 overallProgram Summary Productivity Management Office @
- 14. Key of success 1.Clear TPM policy of top management 2. Alignment between Business plan and TPM plan 3. Management of plan, target and results 4. Priority themes and model activities 5. Incentive for full participation 6. Leadership of each level 7. Budget for TPM activity. Productivity Management Office @
- 15. Tangible result ofTPM ( Example) • P Value-added Productivity x1.5~ Number of Unexpected break down 1/100~ Overall equipment efficiency x1.5~ • Q Quality defect in process 1/10~ • Customer claim ¼~ • C Valuable cost down 30%~ • D Inventory ½ ~ • S Zero accident zero • Environmental pollution zero • M Turnover ½~
- 16. TPM Award 1) Awardfor TPM Excellence, Category B The applicant must score a minimum of 70 points on 100-point Checklist C. 2) Award for TPM excellence category A The applicant must score minimum 70 points on 100 point checklist c 3) Award for excellence in consistent TPM commitment The applicant must score minimum 80 points on 100 point checklist c 4) Special award for TPM achievement The applicant must score minimum 70 points on 100 point checklist B 5) Advanced special awards for TPM achievement The applicant must score minimum 80 points on 100 point checklist A 6) Award for world class TPM achievement The applicant must score minimum 80 points on 100 point checklist S 1st Stage Assessment : May-July 201x 2nd Stage Assessment : October-December 201x +
- 17. • Checklist Cexample TPM policies and objectives 1. 1. TPM policies are planned in relation between company policies and plant/factory policy 2. The relation between TPM target values and management target results are clear 3. The master plan is in an appropriate order as an action plan to achieve TPM 4. TPM policies and objectives are checked using method such as benchmarking that all sections of PQCDSME are displayed corresponding to 8 pillars 5. TPM policies and objectives are have been set forth and observed by all the departments