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TPM Overview and AM Workshop
- 2. 1. Understand theconcept and philosophy of TPM 2. Learn the 8 Pillars of TPM 3. Understand the key concepts of Autonomous Maintenance activities 4. Learn the step by step implementation plan of AM activities 5. Learn the usage of activity boards, meetings and one point lessons to promote TPM goals 6. Understand the critical success factors in sustaining Autonomous Maintenance activities on the shop floor
- 3. Total Productive Maintenance(TPM) is a method to achieve maximum equipment effectiveness through employee involvement Management + Operators + Maintenance
- 4. TPM Willimprove teamwork skills and flexibility between operators and maintenance technicians TPM will improve equipment availability (uptime) TPM saves money
- 5. Equipment isfilthy and stays that way Oil and lubricant leaks are common; lubricators are empty Rotating parts and moving surfaces are encrusted with chips and raw materials
- 7. TPM GOALS: 0 Defect/ 0 Breakdown / 0 Accident 5S & Visual Management AutonomousMaintenance FocusedImprovement EarlyEquipment Management QualityMaintenance Education&Training TPMintheOffice Safety&Environmental Management PlannedMaintenance
- 8.
- 9. Autonomous Maintenanceis maintenance performed by operators Basic maintenance that can easily be performed on a daily basis, e.g. inspection, cleaning, lubrication, etc. Learning about the equipment to understand how it works and be able to spot signs of trouble An employee engagement program as part of the Lean/TPM initiative
- 10. An activityto keep operators busy when product demand is low Doing a favor for maintenance department Performing basic maintenance without a purpose Making operators into skilled technicians
- 11. Operator Maintenance We maintain TPMAttitude Operator Maintenance I use I maintain and fix OLD Attitude
- 12. Predictive Maintenance Breakdown Maintenance Maintenance Activities Preventive Maintenance Robustness Improvement Start Up & YieldLoss Defects & Rework Condition Based Servicing Trends Measurement & Control Effective & Appropriate Repairs Routine Maintenance Cleaning- Refurbishing Daily Equipment Care Lubrication- Tightening Daily Inspection X X X X X XX X X X X Prodn Maint
- 13. Work Systems & Processes Behavior Attitude Culture By improvingequipment & processes…. Changes the way we act…… And the way we think…..
- 14. Organization-led activities Supportedby company and TPM Office Use of audits Determine full implementation of each step Provide feedback on strengths and weaknesses Clarify what needs to be achieved and best way to do it Use of activity boards Meetings and reports
- 15. KEY CONCEPTS • Shopfloor based activities • Operator conducted • Operator enhancing • Team Activity • Autonomous management • TPM Foundation • Part of the job! 3 KEY TOOLS • Activity Boards • Meetings • One Point Lessons
- 19. 1. Ability todetect abnormalities 2. Ability to correct abnormalities and restore function 3. Ability to set optimum equipment conditions 4. Ability to maintain optimum equipment conditions
- 20. 1. Clean andinspect 2. Eliminate problem sources and inaccessible area 3. Draw up cleaning and lubricating standards 4. Conduct general inspections 5. Conduct autonomous inspections 6. Standardize through visual workplace management 7. Implement autonomous equipment management
- 21. Initial cleaningof the machine Identification of Abnormality Hard to access areas Sources of contamination Unsafe conditions
- 22. Cleaning isinspection Inspection is finding problems Problems demand restoration to original proper conditions and improvement to prevent recurrence
- 23.
- 24. Damaged Deformed Noise NonStandard Vibration
- 25.
- 26. Bolts andNuts/ Joints Lubrication Transmission Hydraulics Pneumatics – gas system Electrical Safety
- 27. Missing Loose Shaking Non Standard Bolts / Washers Corroded Damaged Excess / low length Paint on threads and head
- 32. Slackness Tight Damaged Misalignment Noise Pulley/ belt/ gear/ shaft damaged Belt missing Tracking Eccentricity Play
- 34. Oil levellow / high Oil contaminated Oil pressure low / high Oil temperature high Jerks / Vibration Line damage Line not routed properly Noisy pump Pressure gauge not working Oil leak
- 36. Air /gas leak Line damage Line not routed properly Sluggish cylinder movements Filter not drained of moisture Lubricator level low / high Oil flow rate high
- 38. Loose connections Hanging wires Cable not routed properly Cable gland loose Motor generating noise Motor generating more heat Exposed wires Panel inlet filter block Panel / junction box open Screws missing Dust / dirt Connections with open wires
- 41. 1. Don’t beafraid to get your hands dirty during cleaning 2. Remove years of build up grime 3. Open covers and lids on areas you have never checked before. Clean the dirt off every hidden recess of the equipment 4. Don’t just clean the main body of the machine. Remove the grime from auxiliary equipment such as conveyors, gauges, electrical cabinets, and the insides of oil tanks
- 42. 1. Look forloose fastenings, slight vibrations, abnormal temperatures and other problems that can only be detected by touch 2. Watch for worn out pulleys and belts, clogged suction filters, grime on sliding surfaces, and other problems that may lead to functional failures 3. Are cleaning, lubricating, and checking easy to do? Do any large covers get in the way? Are oil inlets located conventionally?
- 45. How todevelop Stage 2? Priority of countermeasures Types and sources of contamination Countermeasures for difficult to clean areas Where-where and why-why analysis Use corrugated paper and acrylic cover to prevent dispersion Use hinge doors instead of fastening screws for ease of opening Keep records of equipment modifications Review unresolved issues
- 48. What islubrication control? Preparation by the Maintenance Department Identify lubricating points and surfaces Allocate routine lubrication tasks Draw lubrication system flowcharts Set tentative lubrication standards Remedy defective area and difficult lubricating areas Set cleaning and lubrication standards Thoroughly implement a color lubrication control system
- 50. Lubrication systemnot working No grease in reservoir No visibility No oil in gear box Lubrication level low/ high Grease / oil leak Without grease nipple and cap Reservoir tank open Excess greasing Oil / grease dust contamination
- 62. The conceptof making a workplace more effective by making the current condition of a workplace obvious at a glance Visual management enhances the smooth flow of information by using visual and audio signals instead of texts or other written instructions It includes a set of techniques that makes operation standards visible so that people can follow them more easily
- 63. Putting updisplays and charts to impress corporate visitors or customers Cluttering empty walls with visuals as if decorating for a birthday or Christmas party A one time effort, only to have the visuals or information become outdated over time Isolated from management standard work
- 74. Process neverends ◦ Metrics ◦ Audits Each process post Results (actual) against Goal (target) ◦ Zero lost time accidents ◦ Zero Defects ◦ Zero Breakdowns ◦ Zero set up time or at least < 10 minutes
- 75. 1. Proper educationand training Are the operators certified? Who certifies them? 2. Development of four equipment related skills 3. Establishment of AM schedule for each operator 4. Autonomous management using activity board and meeting 5. Identifying and reporting problems 6. Participation in problem solving and OEE involvement
- 76. Active leadershipfor TPM initiative AM is owned by Production Department and supported by Maintenance Department Proper operator training, education and skills certification The time required for cleaning and lubrication must be included in the daily schedule Supervisors need to ensure that AM activities are performed
- 78. Engaging employees Aimfor early success Providing active leadership Share success stories Rewards and recognition Continuously improve OEE
Editor's Notes
- #16 Autonomous maintenance is “independent” maintenance carried out by the operators of the machines rather than by dedicated maintenance technicians. This is core concept of TPM or Total productive maintenance, much like TQM (total quality management), TPM gives more responsibility and authority to the operators and releases the technical personnel to do more preventative and improvement works. Unlike traditional maintenance programs where the operators run the machines until they break or become due for maintenance and then hand them to the maintenance department, autonomous maintenance has the operators performing the simpler (and safe) maintenance routines such as lubrication, bolt tightening, cleaning and also inspection and monitoring. As the people that have day to day contact with the machines they are the most familiar with the operation of each machine and with full training can come to understand the functioning of the equipment. This enables them to feel greater ownership for their work and become more in control of how things are done and what improvements are made.