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TPM Overview
yrs
33yrs
yrs
22yrs
yrs
33yrs
yrs
33yrs
FOCUSED
IMPROVEMENT
AUTONOMOUS
MAINTENANCE
PLANNED
PIII MAINTENANCE
PIV
PV
PVI
EDUCATION &
TRAINING
EARLY EQUIPMENT
MANAGEMENT
QUALITY
QUALITY IMPROVEMENT
MAINTENANCE
EFFECTIVE
PVII
ADMINISTRATION
SAFETY &
PVIII ENVIRONMENT
TPM
Progress
Implementation
Expansion
6 Months
1 Year
6 Months
1 Year
Steps 1-7
Step 7
Steps 8-9
Steps 10-11
1. Top Managements
declaration to
introduce TPM
2. TPM Introduction
Training
3. TPM Organization
4. TPM Policy & Goal
5. Master Plan
6. TPM Kick Off
7-(1) Focused Improvement
7-(2) Autonomous Maintenance
TPM Award
Preparation
Production
Production Maintenance Quality Engineering
Purchasing
Sales
Control
Admin.
Focused
Improvement
Autonomous
Maintenance
Planned
Maintenance
Education
&Training
Early
Equipment
Management
Quality
Maintenance
Effective
administration
Safety &
Environment
FI Focus Improvement
Tm
lt
Vn
What
Why
Plan
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Pareto, Histogram, Bo co s
c, lch s sa cha, OEE
How
When
Who
Wher
e
Do
Check
Action
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Kt
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t k hoch cho cng vic
lun
tng lai
sp ti
Pareto, Histogram,
Checksheet, Biu kim
sot, qui trnh,
FI Focus Improvement
Operating
time
Reduced speeds
(machine wear,
substandard material,..)Ideal cycle time = Design Cycle time
= Theoretical Cycle time = Nameplate Capacity
Net
Operating
Time
Fully
productiv
e
Time
OEE = PP x A x P x Q
= (Planning) X Availability X Performance X
Quality
Wasted$
$s
FI Focus Improvement
7 QC TOOL
FI Focus Improvement
7 QC TOOL
7 QC Tool
Tm lc
Mc ch s dng
th
Trc quan d
liu
Biu phn
tn
Quan h
tng h
Biu kim
sot
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qu trnh
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Vn ni
tri
Checksheet
Thu thp
thng tin
FI Focus Improvement
PM ANALYSIS PRINCIPLE
FI Focus Improvement
PM ANALYSIS STEPS
Step 1 : Clarify the Phenomenon
Step 2 : Conduct a Physical Analysis
Step 3 : Identify Constituent Conditions
Step 4 : Study 4Ms for Causal Factors
Step 5 : Establish Optimal Conditions (Standard
Values)
Step 6 : Survey Causal Factors for Abnormalities
Step 7 : Determine Abnormalities to Be
Addressed
Step 8 : Propose and Make Improvements
FI Focus Improvement
5-Why Analysis
5-Why Analysis
Sheet
FI Focus Improvement
FI Focus Improvement
The plant received a PR/R from a customer. (We use 5-Why Analysis to
answer every PR/R.)
The PR/R states that the customer received Regular Cola in the right
container (same for both products) with the Diet Cola label. The order called
for Regular Cola.
The plant has two identical lines that are capable of running either of our two
products. The lines are located immediately beside each other. The only
differences in the products are the syrup and the labels.
The plant runs both lines 24 hours per day. There are three shifts that run
7:00 a.m. to 3:00 p.m., 3:00 p.m. to 11:00 p.m., and 11:00 p.m. to 7:00 a.m.
The date code indicates that the defective product was manufactured at 3:03
p.m.
Defective product has been contained and sorted.
FI Focus Improvement
Define
problem
Regular Cola
with diet cola
label
Why
?
U se
th i
sp
ath
for
Why
the
sp
?
inv ecific
Changeover
es t
n
iga onco
te d
nfo
U se
Why
rm
Oerator not
th i
anc
s
?
eb
pat
certified
Not following
ein
ht
o in
g
procedure
Why
ves
t
Not formal
i ga
?
Why
te w
certification
Not
hy
the ?
procedure
fomalized
pro
Operator
Why
ble
U se
m w procedure
dependent
th i
?
Why
as
Budgetary
s
pa t
not
process: no
ht
det ?
constrains
o in
ect
supervision
Why
ves
Replying of
t
ig a
Why
?
operator to
te t
he
?
follow up
sy s
tem
No formal ic
procedure
roo
Why
Why
monitoring
t ca
u se
?
?
adherence
to
Failure not
procedureWhy
includeed
?
in orginal
FMEA Why
?
Root Cause
Expended to be
covered with
"on-the-job"
training
FI Focus Improvement
FMEA
Getting Started on
FMEA
Understand your
Customer
Needs
=QFD
Ready?
Create
an Effective
FMEA Team
= What we
Define the FMEAare and are
Scope
not working
Determine
3
Effects of
The Failure
Mode
Develop and
Drive
7
Action Plan
Severity Rating
Determine
2
1 Determine
Product or
Failure Modes
Process
of Function
Functions
Determine
66
5
4
Determine
Causes of
Calculate &
Controls
The Failure
Assess Risk
Detection Rating
Mode
Occurrence Rating
FI Focus Improvement
FMEA
The FMEA Worksheet
Resp. &
Product
S
O
D R
Failure Failure
Actions
Target
or
E Causes C Controls E P
Mode Effects
/ Plans Complete
Process
V
C
T N
Date
1
Determine
Product or
Process
Functions
Determine
Effects of
The Failure
Mode
Severity
Rating
Determine
Failure
Modes
of Function
Determine
Causes of
The Failure
Mode
Occurrence
Rating
7
Develop
and
Drive
Action Plan
Determine
Controls
Detection
Rating
Calculate
&
Assess
Risk
p
S
E
V
p
O
C
C
p
D
E
T
p
R
P
N
FI Focus Improvement
None
Low
Moderate
High
Extreme
Severity
FMEA
SeverityofEffect
Rating
Mayendangermachineoroperator.Hazardouswithoutwarning
10
Mayendangermachineoroperator.Hazardouswithwarning
Majordisruptiontoproductionline.Lossofprimaryfunction,100%scrap.Possiblejiglockand
MajorlossofTaktTime
Reducedprimaryfunctionperformance.ProductrequiresrepairorMajorVariance.
NoticeablelossofTaktTime
Mediumdisruptionofproduction.Possiblescrap.Noticeablelossoftakttime.
Lossofsecondaryfunctionperformance.RequiresrepairorMinorVariance
Minordisruptiontoproduction.Productmustberepaired.
Reducedsecondaryfunctionperformance.
Minordefect,productrepairedor"UseAsIs"disposition.
Fit&Finishitem.Minordefect,maybereprocessedonline.
8
7
6
5
4
3
MinorNonconformance,maybereprocessedonline.
Noeffect
FI Focus Improvement
Occurrence
FMEA
<.33
10
1in3
>.33
1in8
Process is not in statistical control.
Similar processes have experienced problems.
1in20
>.51
>.67
1in80
>.83
>1.00
1in2000
>1.17
1in15k
>1.33
Low
>1.50
>1.67
Moderate
High
1in2
Remote
VeryHigh
LikelihoodofOccurrence
Failure Capability
Rate
(Cpk) Rating
FI Focus Improvement
Detection
FMEA
Rating
Moderate
High
4
Controls have a good chance of detecting the existence
of a failure
VeryHigh
Low
VeryLow
Likelihoodthatcontrolwilldetectfailure
6
5
3
FI Focus Improvement
FMEA
The Calculation !
FI Focus Improvement
FMEA
Product
or
Process
Failure
Mode
Failure
Effects
S
O
E Causes C Controls
V
C
D R
Actions
E P
/ Plans
T N
120
Hole OversizeUnable to
Wrong
Ball Gage
5
8
Drilling
Hole Install BP Drill Bit Visual Insp3
Fastener
Used
p
Target
S O D R
Complete E C E P
Date
V C T N
5115
FI Focus Improvement
Step
1
Problem
Step
2
Analysis
Step
3 Solutions
Identify the specific actions that will be taken to reduce the
risk of a similar issue occurring.
- Place a possible solution above the cause that it controls.
- Evaluate the different possible solutions.
- Create a plan for actions or a combination of actions that will
be implemented.
http://www.thinkreliability.com/searchindustry.aspx#in
dustrial
AM Autonomous Maintenance
3 Years
Cleaning/Lubrication procedures.
2. Source of Contamination
-Solve Sources of Contamination and
& Hard-to-Reach areas Hard to Reach areas. (Cleaning, Inspection, Lubrication)
3. Standards of Cleaning
& Lubrication
4. General Inspection
5. Autonomous Inspection
6. Standardize Autonomous
Standardize routine operations related to workplace
management such as quality inspection of products,
Maintenance operations
life cycle of jigs, tools, set up operation and safety.
7.
Autonomous
Management
AM Autonomous Maintenance
AM Autonomous Maintenance
Before
After
AM Autonomous Maintenance
F-Tagging
During
Initial Cleaning
Tag
Tag
Issued
Issued
Afterwards
Every Day Process
Tag
Tag
Restore
Restore
dd
AM Autonomous Maintenance
Monitoring Tags
Tag
Tag
Issued
Issued
Tag
Tag
Restore
Restore
dd
PM Planned Maintenance
PHASE 3
PHASE 4
Improve MTBF
INCREASE TIMELIFE
SYSTEMATIC REPAIR
FAILURE PREDICTION
AUTONOMOU
S
MAINTENANC
E
1 Initial Cleaning
4 Inspection system 5 Entire process
2 Sources of
inspection
contamination,
Hard-to-reach area
3 Standardize
6 A.M. System
7 A.M. Management
1 Evaluate
Equipment & Understand
Current Conditions
PLANNED MAINTENANCE
PHASE 1
2 Repair degradations
and improve weakness
3 Information
system
(Database)
4 Preventive
Maintenance
System
5 -Predictive
Maintenance
System
PM Planned Maintenance
PM
PM -- Main
Main Activities
Activities
Improvement
Improvement
of
of Equipment
Equipment
MTBF
MTBF
Preventive Maintenance
Corrective Maintenance
Maintenance Prevention
Breakdown Maintenance
Support for Autonomous
Maintenance
Improvement
Improvement of
of
Maintenance
MaintenanceSkills
Skills
MTTR
MTTR
Specialized maintenance
skills
PM Planned Maintenance
MTBF=
TIME
FAILURE
MEAN
MTTR=
BETWEEN
TIME
TO
REPAIR
Education
Education&
&Training
TrainingMaster
Masterplan
plan
- Communication manner
- Basic management tools
- Cost measurement
- TPM control
R
SO
VI
G
EN
Process capacity;
PM analysis,
7 QC tools.
Maintenance skills
Line balance...
Management skill-up
Cost Saving Control
OR
W
KE
R
-Basic maintenance,
-Operation & OJT (On job training)
-Simple 5S
-Maintenance procedure, maintenance instruction, Form,
-Company history, rules, HSE
1.
2.
3.
4.
5.
6.
7.
F
AF
ST
5
4
3
2
1
R
EE
6
5
4
3
2
1
IN
For new
staff,
supervisor,
Engineer,
staff,
Worker)
R
PE
SU
4
3
2
1
ADVANCED
EDUCATION
Education
Education&
&Training
TrainingMaster
Masterplan
plan
Step 4: Training and Evaluation
Step 1: Skills/Techniques
Inventory and Hierarchy
Create a list of Operational and Maintenance Skills and Techniques
(Prevention of Maintenance)
Objective
Objective
MinimizeLCC
LCC(=Life
(=LifeCycle
CycleCost)
Cost)of
of equipment
equipmentby
bythe
thefeedback
feedbackofof
Minimize
experiencefrom
fromthe
thedevelopment
developmentstage
stageofof equipment
equipmentand
andproduct
product
experience
View
ViewPoints
Points
Product
ProductDevelopment
Development
Easy-to-manufacture
Defect-free
Competitive
Clarify 4M conditions
-Material
-Method
-Machinery
-Manpower
Equipment
Equipment
Development/Investment
Development/Investment
Free from major losses
Easy to use
Easy to maintain
Easy to clean
Have quick set-up time
Operate with lowest LCC
B SUNG SAU
KHI C SCH
QM Quality Maintenance
Quality
Maintenance
Aim
Aim
Toensure
ensurethat
thataaplant
plantisisininaaperfect
perfectcondition
conditionwhere
where100
100%
%
To
qualitygoods
goodsare
areproduced,
produced,zero
zerodefects
defects
quality
Ensuring high quality through equipment arrangements at
each process
Steps
Steps
Result
ResultOriented
OrientedApproach
Approach
after
afteritithas
hashappened
happened
Cause
CauseOriented
OrientedApproach
Approach
before
beforeitithappens
happens
QM Quality Maintenance
-http://www.tpmconsulting.org/english_show.php?
id=7&engin=TPM%20Literature%20Review,%20concep
t%20and%20structure
-D\TPM\TPM Study guide_nippon
-D\TPM\TPM draft
QM Quality Maintenance
Quality
approach
QUALITY
QUALITYDEFECT
DEFECT
Human Error
Educate operators
Crisis
Quality Assurance
Results
Control
Control
of
Causes
Preventive
Equipment Monitoring
Correspondence between Quality
features and Process conditions or
Equipment Capability
Activities of
Auto -Maintenance
Field Training
QM Quality Maintenance
QM Quality Maintenance
QM Quality Maintenance
QM Quality Maintenance