Transcript No Slide Title

WHAT IS
TPM
W H A T I S TPM ?
• A well defined methodology to optimize resources
& improve performance
• A culture change - “never be satisfied”
•
Team-work and cross functionality
•
Transparency and visibility
•
Discipline and rigour
•
Continuous improvement
•
Wireless real time data collection, data mining and data assessment
16 MAJOR LOSSES
• TPM is a system to organize practical, shop-floor
methods to reduce losses ...
EQUIPMENT
MAN POWER
1- Failure Loss
10- Motion Loss
2- Start up Loss
11- Measure & Adjust
3- Speed Loss
12- Management Loss
4- Set up & Adjustment
13- Line Organisation
5- Idling & Minor Stops
14- Lack of Automation
6- Defects & Rework
7- Shutdown Loss
8- Die, Jig & Tool Loss
MATERIAL
15- NTM, Consumables
ENERGY
9- Energy Loss
16- Yield Loss
16 MAJOR LOSSES
Production
man-hour
loss
Line organisation
man-hour loss
Man (Man time)
Machine (machine
time)
Operational time
Working time
Man Loading
Time
Machine
Loading time
Machine efficiency
Scheduled Downtime
Net
Operational
operational
time
time
Real Net
working operational
time time
Downtime loss
Value Value
added added
time time
Performance loss
Defect in man-hour loss
Energy
Energy input
Effective energy
Material
Defects quality loss
Material input (number, weight)
N. quality products
Ideal weight
of quality
products
major losses obstructing
equipment efficiency
5 major losses obstructing
manpower efficiency
Labour efficiency
W H A T I S TPM ?
in other words :
INCREASE THE RELIABILITY OF THE PLANT
T E C H N I Q U E S
- Cleaning
- Tagging
-5S
- Details: 1 / 30 / 300
- Teams
- Loss Deployment
- Audits
- Communication : Boards
- One Point Lessons (OPL)
o f TPM
C U L T U R E C H A N G E
Losses
EXIT THE “QUICK-FIX CULTURE”
Sporadic loss
Restoration area
in order to return to
previous condition
“Quick-fix zone”
Chronic losses
Objective
Optimal conditions
Zero defects
Innovation area
to achieve optimal conditions
Time
COMPANY LANGUAGES
Man (Man time)
Machine (machine
time)
Source : Juran
Top Management
Language
$
$
Middle Management
Language
$ AND TECHNICAL
Junior Management and personnal Language
TECHNICAL
CAN
SPEAK
TPM ALL
COMPANY
LANGUAGES
TPM ORGANISATION
BOARD
OVERALL
Machine (machine
WCMCOORDINATOR
time)
Man (Man time)
AM=AUTONOMOUS MANAGEMENT
PM= PROGRESSIVE QUALITY
FI=FOCUSED IMPROVEMENT
PLANT WCM
Machine (machine
COORDINATOR
time)
PLANT STEERING
COMMITTEE
STRUCTURE
$
AM PILLAR
PM PILLAR
FI PILLAR
DEPARTMENTAL
COMMITTEE
STRUCTURE
.........
AREA
COMMITTEE
STRUCTURE
TPM TEAM
STRUCTURE
Losses
Actual Cost
LOSS DEFINITION
Cost that can
be attacked
Cost that can
not be attacked
Cost that
Adds
Value
LOSSES OF UPTIME
LOSSES
OF UPTIME
AVAILABILITY
LOSSES
PERFORMANCE
LOSSES
SPEED LOSSES
BREAKDOWNS
QUALITY
LOSSES
SHORT STOPS
START UP
SIZE/ BRAND
CHANGE
DEFECTS
SCRAPS
AUTONOMOUS
MANAGEMENT
TEAMS
PLANNED
MAINTENANCE
TEAMS
PROGRESSIVE
FOCUSED
QUALITY
IMPROVEMENT
TEAMS
TEAMS
These teams attack individual loses with different methodologies
OVERUSAGE
LOSS DEPLOYEMENT OF UPTIME (OEE)
Waste Losses:
Hold Losses:
Speed Losses:
Quality Losses:
Performance Losses:
Short Stops:
100 %
Availibility Losses:
UPTIME
Breakdown
Losses:
Size
Brand Change
Startup
Losses:
UPTIME IS AN INDICATION ON ‘’WHAT WE DO GOOD’’
THE PORTION ABOVE UPTIME THAT SUMS UP TO 100 % SHOWS THE LOSSES
LOSSES NEEDS TO BE DEFINED AND DEPLOYED SYSTEMATICALLY FOR GOOD ANALYSIS