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1、1,A STRATEGY FORPERFORMANCE EXCELLENCE,Total Productive Maintenance,2,Performance Excellence SeriesTraining Module Elements,Executive Overview,Participant manual,Tools Workbook,Knowledge Breakthrough,Lecture notes,Lecture notes,3,Table of ContentsExecutive Overview,Session 1.0Introduction.3Session 2
2、.0Role in Lean Manufacturing.8Session 3.0Role of the Operator in TPM.18Session 4.0Autonomous Maintenance Implementation22Session 5.0Equipment Performance:Measurement&Management.56,TPM,4,Total Productive Maintenance,Do these problems sound familiar?Equipment is always breaking downOperating machines
3、at rated speeds creates defectsSetups and adjustments take too longMinor machine stoppages are eroding productivity,5,Total Productive Maintenance,A series of methods to ensure that process machines are always able to perform their functions so that production is never interrupted.,6,Total Productiv
4、e Maintenance,What it is:1.Optimizes equipment efficiency2.Implements a company wide Preventive Maintenance system3.Involves production equipment designers,operators,and maintenance department personnel4.Involvement from Management down to floor workers5.Implemented through small,self directed team
5、activities,7,Total Productive Maintenance,Typical success results after implementation of TPM:Breakdowns:1/30 to 1/100 of prior levelMachine defects:1/30 to 1/40 of prior levelProductivity:30-100 percent increase,source:K.Shirose,TPM For Workshop Leaders,p.10,8,Performance Excellence:Expanding the S
6、trategy through TPM,IntroductionRole in Lean ManufacturingRole of the Operator in TPMAutonomous Maintenance ImplementationEquipment Performance:Measurement and Management,TPM,9,The Nine types of waste,OverproductionDelays(waiting time)TransportationProcessInventoriesMotionsDefective productsUntapped
7、 resourcesMisused resources,9 Wastes,TPM targets reduction of these equipment oriented wastes,10,Yesterday:Problem=machine breakdown=get around the problemSolution=Work in batches“We use the time it works to mass produce”,TPM:A Lean Manufacturing Method,TPM and one-piece flow:,Today:Objective=One pi
8、ece flow Quality every timeMeans=TPM,“We organize so it works continuously”,11,Goals of TPM,Achieve zero equipment breakdowns and zero defects through prevention.Establish prevention by Maintaining normal conditions Early detection of abnormalities Quick response,12,Present Conditions,Operators view
9、 machines as responsible for major productionAnd limit their roles to equipment operation and inspecting for qualityWhile maintenance workers view their function as responding to recurring breakdowns,13,Maintenance Approaches,Time Based or Planned Maintenance-Periodically scheduled maintenance actio
10、ns.Predictive Maintenance-Maintenance action performed resulting from evaluation of equipment condition.Corrective Maintenance-Maintenance action performed to restore optimal equipment function.Preventive Maintenance-A combination of Time based and Predictive Maintenance and actions taken to sustain
11、 optimal equipment performance and preclude breakdowns.,14,Early Equipment Management,Optimizes equipment selection through:Equipment Life Cycle Cost Analysis:analysis of the sum of all costs(direct and indirect)associated with an item of equipment throughout its period of use.MP Design:activity whi
12、ch is focused on minimizing future maintenance costs and production losses of equipment at the design stage.,15,Total Productive Maintenance,Without TPM,With TPM,MED&Industrial Engineering,Maintenance,MED&Industrial Engineering,Operation,Maintenance,The operator operates,maintenance maintains,etc.,S
13、hared responsibilities,Operation,16,Equipment Maintenance Responsibilities,MED&Industrial Engineering,Autonomous maintenance,Breakdown maintenancePlanned maintenancePredictive maintenance,Maintenance prevention,17,Total Productive Maintenance,Equipment in better working condition,Decrease of breakdo
14、wns,Decrease of in-process adjustments,Optimization of operation speed,Manufacturing defects,Lead-time,Quality the first time,18,Performance Excellence:Expanding the Strategy through TPM,IntroductionRole in Lean ManufacturingRole of the Operator in TPMAutonomous Maintenance ImplementationEquipment P
15、erformance:Measurement and Management,TPM,19,Total Productive Maintenance,TPM,the total approachThe operator is the first line caretakerMaintenance personnel are the specialized caretakers.,20,Division of Maintenance Duties betweenProduction and Maintenance,Depending on knowledge and skills required
16、,responsibility for equipment maintenance tasks needs to be defined:Maintenance TechnicianProduction Operator*Equipment overhaul*Basic lubrication*Special skill tasks*General cleaning*Complex adjustments*Multi-point inspection*High safety risk tasks*Basic adjustments,21,Maintenance Task Allocation b
17、etweenProduction and Maintenance,MaintenanceTechnicians,ProductionOperators,Autonomous maintenance implementation,Volume of maintenance tasks,22,Performance Excellence:Expanding the Strategy through TPM,IntroductionRole in Lean ManufacturingRole of the Operator in TPMAutonomous Maintenance Implement
18、ationEquipment Performance:Measurement and Management,TPM,23,Autonomous means“independent”Autonomous maintenance refers to activities involving operators in the maintenance of their own equipment.,Autonomous Maintenance,24,Autonomous Maintenance,How to make the operator more independent:Make the doc
19、umentation available(manual,maintenance schedule,log book).As a team,define manufacturing/maintenance/MED productive maintenance activities.Show operator how to perform daily checks and take corrective actions.Train in basic operation,maintenance and defect detection techniques.Make daily activities
20、 visibleClearly identify items to supervise,25,Process Critical Machinery&Equipment,Map the process and identify critical equipment,Turning,Drilling,Cutting,Cleaning,Stripping&Painting,Shipping,26,Adverse effects of inadequate cleaning,27,Adverse effects of inadequate cleaning:,Failure-equipment fai
21、lure resulting from dirt and contamination affecting precisionProduct defects-contamination of products or defects arising from insufficient cleaningAccelerated deterioration-dirt and scale buildup shortening useful equipment lifeThroughput loss-reduction in output due to loss of operation speed due
22、 to grime and contamination.,28,Equipment Deterioration,Normal deterioration:deterioration that occurs despite correct use and maintenanceAccelerated deterioration:quicker deterioration occurring due to misuse in operation and neglect of maintenance.,29,Performance,Time,Equipment Breakdown,100%,Time
23、 and Deterioration of Performance,Need for detection of performance decline,30,Cleaning as Detection of Deterioration,Cleaning-reduces accelerated deteriorationPhysical contact with equipment-exposes abnormal operating conditions(i.e.vibration,noisy bearings,leaks,overheating,frayed belts,inoperativ
24、e indicators,etc.)Preventive action taken-extends useful life and avoids breakdowns,31,A good clean-up allows for a good inspection,Noise,Vibration,Heat,Oil,Dirt,Quickly detect,And document,Cleaning as Detection of Deterioration,32,Factors Contributing to Equipment Failure:,Equipment failures,Loose
25、parts,Vibration,Contamination,Improper/InadequateLubrication,33,Eliminate Factors Contributing to Failure:,Secure and tighten all fasteners,fittings,bolts and screws Replace any missing parts Replace any damaged,worn or wrong size parts Resolve all causes of leaks,spillage,spray and scatter,Improve
26、accessibility in order to accomplish Cleaning Lubricating Adjusting Checking,34,Autonomous Maintenance:Tagging Abnormalities,35,Cleaning will uncover problems and undesirable conditions.Attach tag to make problem visibleResolves problems promptly and remove tags.Document plans to address those that
27、cant be removed immediately.,Autonomous Maintenance,36,Before Tags are Removed,Ask The 5“Whys”,Problem:Oil leaks from the hydraulic press1.Why?Clogged filter2.Why?Oil was dirty3.Why?Metal filings got into oil4.Why?Oil fill cap missing5.Why?Misplaced&lost,Find the root cause,Solution!Oil filler cap a
28、ttached to filler neck by a chain(Poka-Yoke),37,Equipment Performance Losses,Downtime losses-time lost to equipment breakdowns,machine adjustmentsEfficiency losses-time lost to start up and operating cycle speeds less than idealDefect losses-time lost to machine related quality defects and recycling
29、.,38,Equipment Performance Losses,39,Assignable Loss versus Common Loss,Defect rate,Time,Assignable loss-corrected by restoring to original conditions,Common loss-reduced by achieving optimal conditions,40,Importance of Lubrication,Some experts estimate 60%of machine breakdowns associated with movin
30、g parts are due to lack of or improper lubrication practices.,41,Lubrication Management?,The need to lubricate equipment correctly and consistentlyaccording to usagewith correct lubricantsin the correct amountat specified fittingsat specified time intervalsensuring coverage of contact areas,42,Visua
31、l Management of Lubricants,GreenBlueOrangeRed w/White stripe,OilGreaseHydraulic fluidSilicone,43,Maintenance Checklists,TPM VERIFICATION LISTAt The Beginning of Each ShiftHydraulic Pressure Leaks(oil,fluids)Caps and hosesSwitchesLights and lampsBodyNoises/vibrationAt The End of Each ShiftCleanMake e
32、ntry in maintenance book,44,1,2,3,4,5,6,7,8,9,10,Example Cleaning and Lubrication for Autonomous Maintenance,45,Basic Training in Equipment,Conduct equipment training for leaders.Leaders then train group members.Operators implement training to correct abnormalities and improve equipment performance.
33、Implement visual controls.,46,Example Skills Matrix,Basic Training in Equipment,47,One Point Lesson,Purpose:To provide specific knowledge about a single topic of importance.Facilitate team training in an easy manner.Discussed on the shop floor.Types:KnowledgeImprovementsSolutions to problems,48,Obje
34、ct Name:Fasteners Subject:IdentificationNumber:Generic types,Date prepared:4/17/00By:John ClarkApproved:Tina Jones,One-Point Lesson Sheet,DepartmentDate trainedName,Purpose:Identification of fastener hardware for repairs and ordering of replacements.,Maint.,Purchasing,Inventory Stores,x,One Point Le
35、sson,Production,49,TPM Deployment Effectiveness through Overlapping Teams,Plant Manager,Staff Manager,Staff Manager,Staff Manager,Dept.Manager,Dept.Manager,Dept.Manager,Supervisor,Supervisor,Supervisor,Supervisor,Operator,Operator,Operator,Operator,Operator,Maximizing Communication&Coordination,Team
36、 leaders,50,Build a Time Based Maintenance System,Determine equipment for time based maintenance,Develop maintenance criteria and intervals,Train for maintenance implementation,Execute periodic maintenance,No,Revise maintenance instructions/parts provisioning,51,Establish an Equipment Failure Databa
37、se,Gather and manage equipment failure information.Analyze for trends and patterns of recurrence.Develop and issue periodic equipment failure summary reports.Include failure summary reports as a meeting agenda item for regular review,discussion and improvement action planning.,52,Predictive Maintena
38、nce as a Diagnostic Tool,53,Predictive Maintenance Deployment,Determine equipment suitable for Predictive Maintenance,Develop diagnostic methods and instructions,Diagnose equipment as defined,Execute repair,Yes,Revise maintenance instructions/parts provisioning,Document repair information,Evaluate a
39、nd revise diagnostic criteria,54,Maintenance Audits,Audits are the most important factor in the successful implementation of an Autonomous Maintenance Program.They:Verify success of implementation at each stepProvide improvement feedbackInstill a sense of achievement and reinforce continuing effort
40、toward goals,55,Maintenance Audits,Example Audit Cycle,56,Performance Excellence:Expanding the Strategy through TPM,IntroductionRole in Lean ManufacturingRole of the Operator in TPMAutonomous Maintenance ImplementationEquipment Performance:Measurement and Management,TPM,57,Overall Equipment Effectiv
41、eness,Overall Equipment Effectiveness=Availability x Efficiency rate x Quality rateAn index of the overall operating performance of equipmentPoints to the need to Eliminate stoppagesIncrease operating speed.Improve quality(less defects,rework,scrap),58,Equipment effectiveness measurement,Overall Equ
42、ipment Effectiveness=Availability x Efficiency rate x Quality rate,59,Tracking Improvement Impacts On Overall Equipment Effectiveness,Improvement Activities,60,The Mission Board:A Roadmap to Action,61,Maintenance Information Management System,Maintenance Information Management SystemOverall Equipmen
43、t Effectiveness,Cost accountingLabor&material costs,Material ControlUsage and inventory,Human ResourcesStaffing&skills requirements,Quality Assurance Product quality Productivity,Maintenance information in relation to other business process systems,62,A Key Strategy In Pursuit Of World Class Performance,Total Productive Maintenance,
