Approach for TPM Implementation 


What is TPM?

…Is Culture that focuses on Improving the Effectiveness of the plant, equipment, and processes through the empowerment of People.

Aims at building up a corporate that thoroughly pursues production system effectiveness improvement (Overall Equipment Effectiveness: OEE).

Constructs a system to prevent every type of loss, for e.g to, achieves “ Zero accident, zero-defect & Zero failure”, based on actual site(Gemba) and Actual things (Genbustu) over the entire life cycle of a production system.

Cover all departments including production, development, marketing, and administration.

Need all and total engagement from top management to frontline employees.

Achieves zero losses by overlapping small-group activities.

Approach for Total Productive Maintenance (TPM) Implementation


Definition :

 To set a goal to maximize equipment effectiveness (Overall effectiveness)

 By establishing a total system for PM for the entire life of the equipment.

 For promoting PM by motivation management, namely by an autonomous small group of activities.
Taking as a prime objective a company structure that pursues production effectiveness to its ultimate limit(comprehensive effectiveness).

 Putting together a practice shop floor system to prevent loss before they occur throughout the entire production system life cycle: zero accident, zero defect, zero breakdowns.

Achieving Zero Losses through overlapping small groups.

TPM Helps to achieve

ZERO BAD
  1. Zero Breakdown
  2. Zero Accident  
  3. Zero Defect
d  TPM- The Maor approaches to creat plant in the 21st Century.


d   8 Pillar of TPM :
         
  1.            Declaration by top management to introduce TPM, Declared in TPM in houses seminars, company magazine.
  2.            Introductory education and campaign for TPM
  3.       Establishing a TPM Promotion Organization committees and subcommittees
  4.       Set Basic principle and target for TPM
  5.          Creation of masters plan for establishing TPM Kick-off of TPM
  6.       .    Kick-Off TPM
  7.           Establishing systems for improving production efficiency
·         Individual Improvement
·         Autonomous Maintenance
·         Planned Maintenance
·         Operation & Maintenance skills upgrading training

8. Establishing initial control system for new product and equipment 
9. Establishing QM(quality maintenance) organization. 
10.Establishing a system to improve the efficiency of administration and other indirect departments
11. Establishing a system to control safety, health, and environment. 
12 Total application of TPM and raising its level.

       TPM Methodology

      Phase-1: Learning Phase 6 Month
                1.       TPM training to top management
                2.       Selection of Model Machine
                3.       Achieve zero BAD. Improve productivity by 30% within 6 Months.
            The result- Good foundation for TPM implementation Buy-in by all employees. 

      Phase-2: Development phase 6 Month
                1.       Select the next Model from a different group
                2.       Achieve zero BAD, Improve productivity by 30% within 3 Months.
                3.       Select Next Model Machine 
                4.       Achieve zero BAD, Improve productivity by 30% within 3 Months.

     Note: Analyze all customer complaints & achieve zero customer complaints, 16 Losses reduction, OEE data monitoring for all machines, Horizontal deployment of kaizen ideas.

      Results: Defect-free supplies, No lines stoppages due to quality problems, Reduce cost by 15%.

        Phase-3: Deployment Phase 12 Months  

                  1. TPM target Master plan
                  2. Training of TPM to the operator 
                  3. Kick-off
                  4. A select a group of machine
                  5. From JH Circle
        Result: Reduced manufacturing cost. No line stoppages improved OEE. Improved workplace.

       Ability to Detect Abnormalities :

      Four Abilities of Conscious operators :

          1.       To discover abnormalities
          2.       To correct abnormalities and restore functioning
          3.       To Set Optimal equipment condition
          4.       TO maintain optimal equipment condition

The ability to detect abnormalities are the first skill operator need to develop during autonomous maintenance

Skill Level-1 (Recognizing Deterioration and Improving Equipment to Prevent it)

         1.       Being able to recognize deteriorated equipment condition as problems
         2.       Master the basic of equipment improvement mastery of this skill require hands-on learning on the machine
          3.       Only by the machine during cleaning and inspection
          4.       Discover a bolt is loose or the motor is vibrating too much
       Note – This kind of learning begins in steps 1 & 2 of AM.

        Skill Level-2 (Understanding Equipment structure and Function)

          1.       Means understand what the vital mechanism of the machine is and know how to clean machines so that it problems flawlessly.
          2.       Draw up a simple machine diagram of the equipment
           3.       Draw the lubrication supply routs

         Skill Level-3 (Understanding the cause of quality defects)

       1.        To learn the habit of logically thinking
       2.       Roots cause of quality problems
       3.       The Relation between equipment precision and product quality
      This Skill Carried out at steps 3 & 7 of AM
         1.       A diagram is drawn in skill level 2 to show which parts of equipment influences quality
         2.       At skill level 3 operator monitors trends in process control limits as well as keeping up daily cleaning and inspection.

         Skill Level-4  (Performing Touting Repairs)

         This is the fourth stage of operator skill enhancement
       1.       Ability to perform basic repairs
       2.       Understand the equipment structure and function
       3.       Learn to find abnormalities that lead to breakdown or qualities of failure.  

       This skill level we learn simple disassembly and repair procedure
        1.       Tightening bolts correctly
        2.       Aligning pulley and gears
        3.       Changing bearing
        4.       Stopping fluid leaks