TPM CYCLE B

Total Productive Maintenance
© 2016 The Leadership Network®
© 2016 Jidoka®
01
Current State and
Criticality Assessment
Cycle B

© 2016 Jidoka®
02
Four Cycle-11 Step TPM
Review
Performance
Criteria &
History
Measurement
& Opportunity
analysis of
KPIs
(incl. OEE)
Equipment
Criticality
Assessment
Condition
Appraisal &
Restoration
plan
Root cause
Analysis &
Problem
Resolution
Individual
& Team Skill
Development
Leadership
&
Behaviours
Audit & Review
Process
MEASURE
CURRENT STATE
& IDENTIFY
OPPORTUNITY
CONDITION
REVIEW
(INCL. SAFETY
ENERGY, &
ENVIRONMENT)
PROBLEM
PREVENTION &
BEST PRACTICE
ROUTINES
FUTURE STATE
REALISATION
THROUGH A HABIT
OF CONTINUOUS
IMPROVEMENT
Feedback
A
B
C
D
Assess
Hidden
Losses/wastes
& Set
Improvement
priorities
Develop
Future Total
Asset Care
Best Practice &
Standard Work
1 2 3
4 5 6
7 8
9 10 11

© 2016 Jidoka®
03
1.0 Sketch the machine process, make sure that you know how it
functions
2.0 Identify the components to the level of replacement parts
3.0 Assess each against the headings of maintainability,
reliabilityetc. and total to agree priorities.
Step 4 - Criticality Assessment

© 2016 Jidoka®
04
Equipment Criticality Assessment Form

© 2016 Jidoka®
05
• Let’s look at an everyday example….
• The Motor car (Worked exercise)
Car Criticality Exercise

© 2016 Jidoka®
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Car criticality Exercise

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7
• Let’s look at another example….
• Taking the example of the data projector.
• What is the critical component?
Another example

© 2016 Jidoka®
8
• Builds Teamwork between Operators & Maintainers
• Understanding of the Equipment Functionality
• Checklist for Condition Appraisal (Step 5)
• Focus for Future TPM Asset Care (Step 6)
• Highlights Safety & Environmentally Critical Items
• Potential Impact on OEE
• Highlights Weaknesses Regarding:-
þEase of Operation
þInherent Reliability
þEase of Maintenance
Outputs

© 2016 Jidoka®
9
EQUIPMENT
DESCRIPTION
Packing Line6 (P6)
1-3 RANKING AS IMPACT ON:
S A P Q R M E C TOT
1. Checkweigher 2 3 3 3 1 1 1 3 17
List all
Elements
Assess all
Elements
Impact on
Six Losses
Optimum
Conditions
• Safety
• Availability
• Performance
• Quality
• Reliability
• Maintainability
• Environment
• Cost
1 = No impact
2 = Some impact
3 = Major impact
Optimum Checkweigher Conditions
• The checkweigher is calibrated (FLOAC)
• The belts are clean (FLOAC)
• The correct format is entered (FLOAC)
• Load cells are clean (FLOAC)
• Motors are in good condition and bearings
are good (FLOAC, PM, condition
monitoring)
• All rollers are free and easy to rotate
(FLOAC, PM, condition monitoring)

© 2016 Jidoka®
10
Condition Appraisal

© 2016 Jidoka®
11
Review
Performance
Criteria &
History
Measurement
& Opportunity
analysis of
KPIs
(incl. OEE)
Equipment
Criticality
Assessment
Condition
Appraisal &
Restoration
plan
Rootcause
Analysis &
Problem
Resolution
Individual
& Team Skill
Development
Leadership
&
Behaviours
Audit & Review
Process
MEASURE
CURRENT STATE
& IDENTIFY
OPPORTUNITY
CONDITION
REVIEW
(INCL. SAFETY
ENERGY, &
ENVIRONMENT)
PROBLEM
PREVENTION &
BEST PRACTICE
ROUTINES
FUTURE STATE
REALISATION
THROUGH A HABIT
OF CONTINUOUS
IMPROVEMENT
Feedback
A
B
C
D
Assess
Hidden
Losses/wastes
& Set
Improvement
priorities
Develop
Future Total
Asset Care
Best Practice &
Standard Work
1 2 3
4 5 6
7 8
9 10 11

© 2016 Jidoka®
12
• Go to the machine and systematically inspect every square
centimetre for deterioration and hence refurbishment
needs.
• Look for:
– Dirty or neglected equipment
– Disconnected hoses
– Missing nuts and bolts producing visible instability
– Steam leaks and air leaks
– Air filter drains that need cleaning
– Jammed valves
– Hydraulic, lubricating and oil leaks
– Measuring instruments too dirty to read
– Abnormal noises in pumps and compressors
• Pay particular attention to critical components. They
should be kept in optimum condition
Step 5 - Condition Appraisal
(Spot the Rot)

© 2016 Jidoka®
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Step 5a - Condition Appraisal
Sort-Should these bags be here?
Opportunitiesfor better visual management?

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Spot the Rot
What is the optimum setting??

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The condition appraisal will help you to organise the equipment
initial cleaning (an in depth condition appraisal)
Step 5 - Condition Appraisal
This is all part of the “Can Do” Activity
Positive Effects
Restore & Eliminate
Abnormalities
Discovering
Abnormalities
Checking
Cleaning
Attitude Becomes
Pride in
the
workplace

© 2016 Jidoka®
16
• Go to the assigned Area and in 30 minutes find as many
things wrong, no matter how small, incidental or apparently
“trivial”. If it’s not as you would expect it or want, then list it!
• Take some close-up photographs to illustrate some of your
examples
• Include the Workplace Organisation as well as the
Equipment itself.
• When you think you’ve finished, re-look and find 10 more
things wrong.
• Complete only the ‘Description’ column at the Area and the
other columns back at the Training Room
Spot The Rot’ Exercise

© 2016 Jidoka®
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Item
No
Description Safety
Issue?
Environment
Issue?
Potential Impact of the
OEE?
Yes No Yes No High Med Low Zero
Spot the Rot Form

© 2016 Jidoka®
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TEAM
Total
Issues
Safety
Issues
Environmental
Issues
OEE Impact
of H,M & L
TOTAL
%
Spot the Rot Summary

© 2016 Jidoka®
19
1. TPM is about positive obsessive attention to detail.
2. Use our given senses of Look, Listen, Smell, Feel /Touch, Discuss.
3. Even the smallest thing wrong can develop into a major problem. At best
it will stay as it is. At worst it will deteriorate. It certainly won’t get better
on its own !
4. Spotting what’s wrong is only half of the solution. Correcting the
problem with a permanent ‘100 year fix’ is the other half.
5. Many small problems have potential safety and/or environmental
issues.
6. Some will eventually impact on the OEE
7. In the real TPM “Cleaning is Inspection.... is spotting deterioration.... is
catching it before it becomes catastrophic.... is pride in the workplace....
is a “hassle” free shift.... Resulting in ‘’Pride of Ownership”
Spot the Rot Exercise-
Key Learning Points

© 2016 Jidoka®
20
• The objective of the Restoration or Refurbishment
Programme is to set up a Repair and Replacement Plan,
based on the Condition Appraisal (Step 5b )
• The plan will provide a detailed summary of actions to be
co-ordinated by the team and will include:
– Dates and Timescales
– Resource (labour, materials, time)
– Responsibilities
– Control and feedback (Management of Change)
• To aid Planning and Completion of Refurbishment Tasks, it
may be helpful to categorise up to three work packages:
– On the Run (Low Cost/Easy to Do/No Outage)
– Minor Planned Outage (8 to 24 hours)
– Major Planned Outage (involving Redesign/Fabrication).
Step 5b - Restoration Plan

© 2016 Jidoka®
21
Review
Performance
Criteria &
History
Measurement
& Opportunity
analysis of
KPIs
(incl. OEE)
Equipment
Criticality
Assessment
Condition
Appraisal &
Restoration
plan
Root cause
Analysis &
Problem
Resolution
Individual
& Team Skill
Development
Leadership
&
Behaviours
Audit & Review
Process
MEASURE
CURRENT STATE
& IDENTIFY
OPPORTUNITY
CONDITION
REVIEW
(INCL. SAFETY
ENERGY, &
ENVIRONMENT)
PROBLEM
PREVENTION &
BEST PRACTICE
ROUTINES
FUTURE STATE
REALISATION
THROUGH A HABIT
OF CONTINUOUS
IMPROVEMENT
Feedback
A
B
C
D
Assess
Hidden
Losses/wastes
& Set
Improvement
priorities
Develop
Future Total
Asset Care
Best Practice &
Standard Work
1 2 3
4 5 6
7 8
9 10 11

© 2016 Jidoka®
22
Step 6 - Cleaning is Inspection
Object of Cleaning:
Remove dirt, dust
& other
contaminants &….
Prevent accelerated
deterioration
By means of cleaning…
Touch every part of
the equipment
By means of
touching…
Discover malfunctions
in each part
(overheating, vibration,
Abnormal noises,
breakdowns)
Constantly check changes
Prevent problems from
occurring

© 2016 Jidoka®
23
Understanding Equipment
Deterioration
Two Types
Of
Deterioration
Natural
Accelerated
Age
Wear
Corrosion
Material Property Changes
Design Weaknesses
Environment Masks the Obvious
Conditions of use not Heeded
Failure to Maintain Basic Conditions

© 2016 Jidoka®
24
• TPM is centred on Teamwork betweenthe Operator
and the Maintenance Technician by taking shared
responsibility for the health and reliability of their
Equipment Assets So we need to view and consider
both roles together in order to define who does
what and hence the why, when and how.
• We encourage the analogy that healthy equipment
is just like a healthy body. In this scenario the
Operator is the Nurse of the Asset (the patient) and
the Technician is the Doctor (and occasionally the
Surgeon) of the Asset.

© 2016 Jidoka®
25
Effective Maintenance in the Lean
Enterprise with a Future
Daily
Prevention
Measure
Deterioration
Inject Before
Breakdown
Routine Service
Clean
Adjust
Inspect
(Autonomous Maintenance
Monitoring
&
Prediction
(Condition Based
Monitoring)
Timely
Preventative
Maintenance
(Fixed Interval
PM Schedules)
Healthy Equipment is like a Healthy Body!!

© 2016 Jidoka®
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Eliminating Breakdowns and other
‘Unplanned’ Events - The Reality
For Every 100 Unplanned Breakdowns or Stoppages:
➢ 40 Can be eliminated by refurbishing and hence restoring
equipment to standard conditions (Step 5)
➢ 20 Can be eliminated by applying appropriate Daily Front Line
Operator Checks (Step 6) and Best Practice Routines of
Operation (Step 8)
➢ 25 Can be eliminated by applying regular and relevant Condition
Monitoring and Planned Maintenance (Step 6)
➢ 15 Can be eliminated by designing out physical weaknesses in
the equipment (Step 7)

© 2016 Jidoka®
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• In order to keep the equipment to its restored state
and standard, it is vital to divide the Total Asset
Care into three elements:
• Front Line Operator Asset Care Checks.
– Abbreviated to FLO’AC’s and carried out on a shift or day-
by-day or even weekly basis-not requiring spanners or
screwdrivers but making maximum use of visual
indicators, in order to make it easy to do right, and
difficult to do wrong. The operator therefore starts to
carry out the more interesting tasks and progressively
expand their knowledge and capability. Floac check
generally take less than 10 mins.
Ongoing Asset Care

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• Condition Based Monitoring.
– Abbreviated to CBM routines which are selectively
applied using the well proven technologies of
thermography, oil debris analysis and vibration
monitoring-but also recognising that the best condition
monitor ever invented is the Operator using their own
senses of look, listen, feel & touch-(with the proviso that
initially this excludes anything electrical )
•
Ongoing Asset Care

© 2016 Jidoka®
29
• Planned Maintenance schedules.
– Referred to as PM’s which are usually based on a
combination of fixed interval and /or post inspections
and include spares provisioning
Ongoing Asset Care

© 2016 Jidoka®
30
• There are major benefits of this overall approach
for the Maintenance Technician
– They can spend more time on design and engineering
out problems
– Less work is outsourced
– More knowledge and ability is developed in-house
– The Technicians themselves feel more motivated and
more valued
• For the operator
– Opportunity for skill development
– Better understanding of the work that they do
– Respected and valued for their opinions
Ongoing Asset Care

© 2016 Jidoka®
31
• In the real TPM “Cleaning is Inspection.... is
Spotting Deterioration.... is Catching it before
it becomes Catastrophic.... is pride in the
workplace.... is a “hassle free’’ shift....
Resulting in ‘’Pride of Ownership”.
Using our senses

© 2016 Jidoka®
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Sight Touch Hear Smell Taste
Vibration ➼ ➼ ➼
Leaking ➼ ➼ (➼)
Over Heating ➼ ➼ ➼
4th Reason ?
The Link with Human Senses

© 2016 Jidoka®
33
Sight Touch Hear Smell Taste
Vibration ➼ ➼ ➼
Leaking ➼ ➼ (➼)
Over Heating ➼ ➼ ➼
They go BANG !! ➼ ➼ (➼)
The Link with Human Senses

© 2016 Jidoka®
34
• Three key factors about those Front Line Operator
Asset Care Checks….
– They quite probably don’t get done by anyone at the
moment (so it’s not a hidden agenda to get the Operator
to do the Maintainer’s job) and ….
– They do not involve using any spanners, screwdrivers- far
less voltmeters !
– The checks are developed by both the Operator and the
Maintenance Technician – Who also helps train the
Operators to carry them out via Single Point Lessons and
Standard Work
Developing FLOACs

© 2016 Jidoka®
37
DEVELOP ASSET CARE LISTS, INSPECTION AND PM’S
Step 6 - Develop Future
Total Asset Care
Overall Plan (6)
Critical
Assessment(4)
Condition
Appraisal(5a)
Refurbishment
Plan(5b)
CMMS
Pre-Programmed
Technical/ServicingTimetable
Maintainer
PPM’s
Shared
Responsibility
CBM
Operator FLAC
ASSET
Spares List
FEEDBACK
Machine-side
plus
Visual Indicators
Single
Point
Lessons
OPERATOR/MAINTAINER
TRAINING RECORDS
ROUTINE ASSET
CARE
Timetable
(Machine-Side)
Step 8

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38
• Review Criticality analysis work sheet.
• Review condition appraisal or ‘Spot the Rot’
assessment form
Work sheets

TPM CYCLE B

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TPM CYCLE B