TPM courtesy in part of motorola SPS

Courtesy, in part, of Motorola SPS.
Thank You!

WelcomeTo

Cayman Systems USA 513 777-3394
©1998 Revision A 980810

TPM Awareness Information

1


Courtesy, in part, of Motorola SPS.
Thank You!

About T.P.M.
After World War ll. Japanese industries determined that to complete successfully in the world market
they had to improve the quality of their products. to do so, they imported management and manufacturing
techniques from United States and adapted them to their circumstances. Subsequently, their products became
known throughout the world for their superior quality, focusing world attention on Japanese- style
management techniques.
TPM DEVELOPMENT PROGRAM
Implementing Total Productive Maintenance
Seiichi Nakajima.

Cayman Systems USA 513 777-3394
©1998 Revision A 980810

TPM Awareness Information

2


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WHAT IS T.P.M. ??
Definition of T.P.M :
T.P.M. IS: A PRODUCTIVE MANUFACTURING SYSTEM with the TOTAL
Participation of: Managers, Supervisors, Engineers,
Technicians and Operators.
T.P.M. Includes the Following Benefits:
• Maximize Overall Equipment Effectiveness
• Establishment a Complete System of Maintenance for the Machine Entire
Life
• Create a Better Work Environment, Promoting the Participation for All
Employees

Cayman Systems USA 513 777-3394
©1998 Revision A 980810

TPM Awareness Information

3


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T.P.M. = Medical Science of Equipment

PRODUCTION

Foton

AUTOMATION

B-820

VIDEO-AUTO DIE-BONDER MODEL 8030A

POWER
HEATER

Cayman Systems USA 513 777-3394
©1998 Revision A 980810

TPM Awareness Information

4


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The Main objective of TPM is :
Zero Interruptions
Zero Defects
Zero Accidents
Throughout total employees participation from Top Management to Operators,

based in the following activities:

Autonomous Maintenance
• Planned Maintenance
• Individual Improvement
• Quality Maintenance
• Early Equipment Management
• Education/Training (People Development)
• Safety

Cayman Systems USA 513 777-3394
©1998 Revision A 980810

TPM Awareness Information

5


Courtesy, in part, of Motorola SPS.
Thank You!

PILLARS OF TPM
A
U
T
O
N
O
M
O

U
S

M
A
I
N
T
E
N
A
N
C
E

Q
U
A
L
I
T
Y

M
A
I
N
T
E
N

A
N
C
E

P
L
A
N
N
E
D

M
A
I
N
T
E
N
A
N
C
E

I
N
D
I
V

I
D
U
A
L

I
M
P
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O
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E
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N
T

T
R
A
I
N
I
N
G

P
E
O

P
L
E
D
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V
E
L
O
P

S
A
F
E
T
Y

E
H
S

E
A
R
L
Y
E
Q
U

I
P

M
A
N
A
G
E
M
E
N
T

5S´s

Cayman Systems USA 513 777-3394
©1998 Revision A 980810

TPM Awareness Information

6


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T.P.M.
Total Productive Manufacturing
People , Equipment and Product

Improvement by Working Together.

EXCELLENCE

Cayman Systems USA 513 777-3394
©1998 Revision A 980810

TPM Awareness Information

7


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PLANT
OVERVIEW
PLANT
OVERVIEW

Cayman Systems USA 513 777-3394
©1998 Revision A 980810

TPM Awareness Information

8


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TPM
Self Assessment
PLANT
OVERVIEW

TPM
Self Assessment

Cayman Systems USA 513 777-3394
©1998 Revision A 980810

TPM Awareness Information

9


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TPM Self Assessment
Background:

∆1991 First attempt to implement TPM.

∆ TPM consultant provides training to selected Managers,
Supervisors and Engineers.
∆ One coordinator with experience in Process and Maintenance
is assigned to lead TPM.
∆ Literature and materials, prepared and distributed.

Lack of support and involvement results on failing the
implementation.
Cayman Systems USA 513 777-3394
©1998 Revision A 980810

TPM Awareness Information

10


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TPM Self Assessment
1996

∆ One Staff Mgr. is assigned to lead the TPM Implementation
∆
∆
∆
∆
∆

plant wide.
A core team is formed on 2Q/96 with key people from different
departments to coordinate the implementation.
Model equipment is selected based on bottle neck operation.
Equipment conditions analysis performed.
Most of the teams cover the initial cleaning.
Activities are focused on six big losses detected and 5 S´s

implementation.

Cayman Systems USA 513 777-3394
©1998 Revision A 980810

TPM Awareness Information

11


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Asia
Benchmarking
PLANT
OVERVIEW

TPM
Self Assessment

Asia
Benchmarking

Cayman Systems USA 513 777-3394
©1998 Revision A 980810

TPM Awareness Information

12

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TPM Benchmarking
Asia Facilities
Facility 1
Facility 2
Facility 3
Committee:
Objective:

Cayman Systems USA 513 777-3394
©1998 Revision A 980810

1996
April
May
June

4 Chosen Folks
Learn from Asia success experiences in TPM
implementation and come up with directions for
Plant implementation.

TPM Awareness Information

13

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Benchmarking Conclusions
Total management involvement.
T.P.M. Manager (dedicated).
A well defined implementation process.
Provide people with time to work on it. ( 4- 6 Hr./wk ).
Each staff has their own T.P.M. Promoter full time.
Focused in Consultant X model.
Focused in just one product line per area.
Budget assigned for consulting and external training.

Cayman Systems USA 513 777-3394
©1998 Revision A 980810

TPM Awareness Information

14


Courtesy, in part, of Motorola SPS.
Thank You!

PLANT
OVERVIEW

TPM
Implementation

TPM
Self Assessment

Asia
Benchmarking

TPM
Implementation

Cayman Systems USA 513 777-3394
©1998 Revision A 980810

TPM Awareness Information

15


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IMPLEMENTATION/CONSULTANT

* Q3 1996, Consultant X is selected to be Consultant.
* Training of Managers, Team leaders and Team members
* Master Plan Defined
* TPM. implementation initiated according to Consultant X recommendations

Cayman Systems USA 513 777-3394
©1998 Revision A 980810

TPM Awareness Information

16


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T.P.M. POLICY
# ESTABLISH AN INTEGRATED STRUCTURE TO PROMOTE T.P.M.
AS A COMPANY CULTURE.
# MAXIMIZE OVERALL EQUIPMENT EFFECTIVENESS
# TOTAL EMPLOYEE INVOLVEMENT.
# CULTIVATE EQUIPMENT & PROCESS RELATED EXPERTISE THROUGHOUT
SHOP FLOOR. ( Autonomous Maintenance, Planned Maintenance etc..)
# ESTABLISH A RELIABILITY AND MAINTAINABILITY SYSTEM TO MAXIMIZE
EQUIPMENT LIFE TIME. (Planned Maintenance Autonomous Maintenance,
Individual Improvement, Early Equipment Management.)
# ALL EMPLOYEES MUST PARTICIPATE IN T.P.M TRAINING PROGRAM.
# ALL AREAS MUST FOLLOW T.P.M. ESTABLISHED GUIDE LINES.
# DEPARTMENT HEAD IS RESPONSIBLE TO ACCOMPLISH AND SUPPORT
T.P.M. GOALS.
Cayman Systems USA 513 777-3394
©1998 Revision A 980810

TPM Awareness Information

17

Courtesy, in part, of Motorola SPS.
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T.P.M. PLANT WIDE STRUCTURE
TPM
Responsible
Plant Manager

T.P.M. Office

5 ´s

Quality
Maintenance

Cayman Systems USA 513 777-3394
©1998 Revision A 980810

Autonomous
Maintenance
Early
Equipment
Management

Planned
Maintenance

Safety

TPM Awareness Information

Individual
Improvement

Training
People
Development

18


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PROMOTION STRUCTURE
(OVERLAPPING SMALL GROUPS)

PLANT
MANAGER
STAFF MANAGERS
OPERATIONS
TPM PILLARS
& PROMOTION
OFFICE

DEPARTMENT
MANAGERS
DEPARTMENT
SUPERVISORS

TPM
PROMOTERS

TPM TEAM

Cayman Systems USA 513 777-3394
©1998 Revision A 980810

TPM Awareness Information

19


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VISION STATEMENT:
TPM
PLANT WIDE
IMPLEMENTATION

Q1 2000

Cayman Systems USA 513 777-3394
©1998 Revision A 980810

TPM Awareness Information

20

Courtesy, in part, of Motorola SPS.
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T.P.M. IMPLEMENTATION ACTIVITIES
MANAGER TEAMS

Cayman Systems USA 513 777-3394
©1998 Revision A 980810

TPM Awareness Information

21


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PREPARATION / PLANNING STAGE
# DEFINE PILOT LINES
# AMOUNT OF MACHINES INCLUDED PER LINE
# DEFINE CORE TEAM MEMBERS OF EACH LINE
# SELECT TEAM MEMBERS PER MACHINE
# START ACTIVITIES IN PILOT MACHINES (bottle neck.)

Cayman Systems USA 513 777-3394
©1998 Revision A 980810

TPM Awareness Information

22


Courtesy, in part, of Motorola SPS.
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Line and Machine Selection

B-820
B-820

Machine 1

Machine 2
N-661

POWER
HEATER

Machine 3

Machine 4
B-609
B-609

V-701
V-701

Cayman Systems USA 513 777-3394

©1998 Revision A 980810

TPM Awareness Information

23


TPM Implementation Plan
ACTIVITIES
DEFINE STRATEGIES
MASTER PLAN
PREPARATION
ORGANIZATION
STAGE
INTRODUCTION TRAINING
PUBLICITY

I
M
P
L
E
M
E
N
T
A
T
I
O

N

S
T
A
R
T

T
A
R
G
E
T

MODEL MACHINES
Machine 1
Machine 2
Machine 3
Machine 4
EXTEND
IMPLEMENTATION
SIMILAR
PRODUCTION LINES
COMPLETE
IMPLEMENTATION
DEFINED AREAS

1996

1997

1998

1999

Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2

1

T
P
M
K
I
C
K
O
F
F

2

2000

Q3 Q4 Q1 Q2

3

AUTONOMOUS MAINTENANCE

&
REDUCE 6 BIG LOSSES
EXTEND SIMILAR MACHINES

30%
to
50%

100%


TPM 90 D ays Explosion Plan
O ctober
w w 40

N ovem ber

M achine 1
PILO T TEA M

PILLA RS

Step 3
Planned m aintenance
6 big losses
IndividualIm provem ent
10 Extension team s
step 1-2
19 Extension team s
Start step 1

M achine 2
PILO T TEA M
Step 2-3
Planned m aintenance
6 big losses
IndividualIm provem ent
11 Extension team s
step 1-2
M achine 3
PILO T TEA M
Step 2-3
Planned m aintenance
6 big losses
IndividualIm provem ent
6 Extension team s
step 1-2
2 Extension team s
Start step 1
M achine 4
PILO T TEA M
Step 1-2
Planned m aintenance
6 big losses
IndividualIm provem ent
4 extension team s
Start step 1
IM PLEM EN TA TIO N M O D EL
GA N TT
TPM A ctivity Board Extension Team s
Server

D ata collection
GM A udit
Team presentations
TPM O ffice A udit
Consultant visit
TPM M eeting
LocalBO O T CA M P
TPM M CO E M EETIN G, JA PA N
Pillars m eeting

D ecem ber

w w 41 w w 42 w w 43 w w 44 w w 45 w w 46 w w 47 w w 48 w w 49 w w 50 w w 51

w w 52

Start
Start
Start
Start
4 mc
7 mc

3 mc
6 mc

3 mc
6 mc

Start

Start
Step 1

Step 2
B-613

3 mc

Step 1
2 mc 2 mc

B-601

L-604

Start
Start
Start
Start
2 mc

4 mc

Start
Start
Start
Start
Start
a-820 a-821 J-701 J-601

M1

M2

M3

M4