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Slide 1: 

WELCOME

AGENDA : 

PRESENT SCENARIO IN INDUSTRY FREQUENTLY USED TERMS IN THE PRESENT INDUSTRY TPM AGENDA

Slide 3: 

Selling Price = Raw material + Manufacturing cost + Profit Operating cost + overheads Actual + Waste N.V.A (Non value Activities) What was excellent yesterday, will be obsolete today What is best today – will be very common tomorrow PRESENT SCENARIO IN INDUSTRY

Slide 4: 

Due to competition for survival Need of the hour is CHANGE Change the way, we THINK MANAGE PLAN DESIGN MANUFACTURE AND SERVE CUSTOMERS In totality we must change virtually everything we must bring in NEW ATTITUDE NEW SYSTEMS NEW TOOLS

FREQUENTLY USED TERMS IN THE PRESENT INDUSTRY : 

FREQUENTLY USED TERMS IN THE PRESENT INDUSTRY ISO 9001 – 2008 - International organization for standardization TS 16949 - Technical specification 16949 (for Automotive Industry) TQM - Total quality management TPM - Total productive maintenance JIT - Just in time QCDS(MS) - Quality, Cost, Delivery, Service, Morale, Safety KAIZEN - Do it Better, Continual improvement

Slide 6: 

FMEA - Failure Mode Effect Analysis DFMEA - Design Failure Mode Effect Analysis PFMEA - Process Failure Mode Effect Analysis

Slide 7: 

Tolerance USL, LSL - Upper Specification limit, Lower specification Limit CPK - (Process Capability Index) CP - Process Capability UCL - Upper control limit LCL - Lower control Limit Zigma PPM - Parts Per million STR - Stock Turn Rotation ETR - Employee Turn Rotation Low cost Automation Zero breakdown Quality Circle Single piece flow, Lean manufacturing

Slide 8: 

VAVE - Value Added ,Value Engineering 5S SERI - SORTOUT SEITON - ARRANGE SEISO - CLEAN SEIKUTZU - MAINTAIN SETSUKE - TRAINING 3M MURI - UNNATURAL MUDA - WASTE MUDA - UNEVENNESS, INCONSISTENCY

Slide 9: 

7 QC – Problem Solving Tools CHECK SHEETS STRATIFICATION PARTEO DIAGRAM CAUSE & EFFECT DIAGRAM (FISHBONE DIAGRAM) HISTOGRAM SCATTER DIAGRAM CONTROL CHARTS

Slide 10: 

DEMING CYCLE (PDCA) PLAN CHECK ACTION DO

Evolution of Maintenance : 

Evolution of Maintenance Breakdown maintenance Preventive Maintenance (Concept introduced in 1951 – planned inspection & Replacement) Maintainability and methods improvement (beyond restoration, modification of procedure – less breakdown) Maintenance Prevention (MP) (In Design) Productive Maintenance Total Productive maintenance (TPM) (Aiming maximum Productivity Profitability)

ACTIVITY : 

ACTIVITY 1. Preventive maintenance2. Improvement related Maintenance3. Maintenance Prevention

Presentation onTotal Productive MaintenanceBy R. DURAISAMYHOS / PRINTING : 

Presentation onTotal Productive MaintenanceBy R. DURAISAMYHOS / PRINTING


WHAT IS TPM? : 

WHAT IS TPM? TPM IS A NEW WORK CULTURE THAT IMPROVES THE INTERFACE PROBLEMS AMONG ALL DEPARTMENTS TO ACHIEVE COMPANY’S COMMON GOAL. TPM PROVIDES A SYSTEM FOR BOTH MAINTENANCE AND PRODUCTION TO WORK TOGETHER AS A TEAM TO IMPROVE PRODUCT QUALITY, EQUIPEMENT AVAILABILITY AND EQUIPEMENT RELIABILITY. TPM PROVIDES A “SHARED TASK ZONE” IN WHICH BOTH PARTIES TO PERFORM SAFELY THE TASKS INDENTIFIED BY THE TEAM. FINALLY,TPM IS PARTICIPATION OF ALL EMPLOYEES IN AN ORGANIZATION TO ELIMINATE ALL LOSSES THAT IMPEDE EFFICIENCY.

WHY WE NEED TPM IMPLEMENTATION? : 

WHY WE NEED TPM IMPLEMENTATION? TO CHANGE FROM A REACTIVE CRISIS MANAGEMENT TO PROACTIVE APPROACH TO ELIMINATE VARIOUS LOSSES AND UNPLANNED DOWNTIME TO INCREASE EQUIPMENT EFFECTIVENESS TO ELIMINATE REJECTIONS/SCRAP TO CREATE A SAFE WORK ENVIRONMENT TO REDUCE OPERATING COSTS

TPM GOAL : 

TPM GOAL AIM: TO MAXIMIZE THE EFFICIENCY OF THE EQUIOPMENT THROUGHOUT THE ENTIRE LIFE CYCLE OF MACHINE i.e., BY MAKING ALL THE “ LOSSES” TO “ ZERO” i.e., Zero Break Down Zero Defect Zero Accident

NINE PILLARS OF TPM : 

NINE PILLARS OF TPM QUALITY MAINTENANCE SAFETY, HEALTH & ENVIRONMENT TOTAL EMPLOYEE INVOLVEMENT

The 7 Steps to Autonomous maintenance : 

1. Initial clean up- discovering faults 2. Eliminate causes of contamination /make cleaning easier 3. Prepare tentative cleaning and lubrication standards 4. Improve inspection and technical skills 5. Autonomous checking of machines 6. Standardize procedures and work place rules 7. All out autonomous maintenance The 7 Steps to Autonomous maintenance JISHU HOZEN

JISHU HOZEN : 

JISHU HOZEN Cleaning Of machine Tagging Of Abnormalities To Find & Eliminate Abnormalities Reduce effect of Abnormalities resulting in Breakdown Accidents Rejections Cost Environmental pollution

JISHU HOZEN - STEP IINITIAL CLEANING AND INSPECTIONCLEANING AND INSPECTION MARK THE CRUCIAL START OF JISHU HOZEN ACTIVITIES : 

JISHU HOZEN - STEP IINITIAL CLEANING AND INSPECTIONCLEANING AND INSPECTION MARK THE CRUCIAL START OF JISHU HOZEN ACTIVITIES Three Main Things To Remember CLEANING IS INSPECTION INSPECTION MEANS FINDING PROBLEMS CORRECTING PROBLEMS LEAD TO RESTORATION OF ORIGINAL CONDITION OR IMPROVEMENT WHAT IS ABNORMALITY? ABNORMALITY (FUGUAI) IS MINIOR DEFECT (OR) SLIGHT DEFECT IT IS NG CONDITION HENCE, ABNORMALITY IS THE CONDITION & MALFUNCTION IS THE RESULT.

JISHU HOZEN - STEP 2ELIMINATE SOURCES OF PROBLEMS AND HARD TO ACCESS AREAS : 

JISHU HOZEN - STEP 2ELIMINATE SOURCES OF PROBLEMS AND HARD TO ACCESS AREAS THE JISHU HOZEN STEP 2 ACTIVITIES ARE: Eliminate sources generating dust, dirt & stains Improve areas where splashing and flying are existing Improve places that are hard to access for cleaning, lubricating, retighting and inspection

Slide 27: 

EXAMPLE : Repairing a leaking pipe joint or reducing Lub oil volume to prevent an overflow. Installing a localized guard to prevent the scattering of chips during a machining operation with coolant stream. The location of parts or design of covers make areas of equipment difficult to clean, lubricate and inspect.

JISHU HOZEN - STEP 3 : 

JISHU HOZEN - STEP 3 SET TENTATIVE CLEANING LUBRICATION AND INSPECTION STANDARDS (CLI STANDARDS) AFTER STEP 1&2, THE EQUIPMENT WILL BE IN “as it should be” CONDITION With the gained experience in steps 1& 2, operators determine the optimal conditions for cleaning, lubrication and inspection of the equipment.

Slide 29: 

Preliminary work standards with the help of manager and maintenance are prepared to maintain optimal conditions of the equipment Work standards specify what should be done, where, why, how, and when. The team decides which part of the machine needs cleaning, how often, method to use and what to inspect while cleaning and how to judge conditions are normal.

JISHU HOZEN - STEP 4( CONDUCT GENERAL INSPECTION TRAINING AND DEVELOP INSPECTION PROCEDURES) : 

JISHU HOZEN - STEP 4( CONDUCT GENERAL INSPECTION TRAINING AND DEVELOP INSPECTION PROCEDURES) IN JISHU HOZEN STEPS 1-3, OPERATORS LEARN TO PREVENT DETERIORATION AND TAKE CONTROL OF THE BASIC CONDITIONS OF THE EQUIPMENT. IN JH STEP – 4 OPERATOR ACQUIRES EQUIPEMENT RELATED TECHNICAL KNOWLEDGE AND TROUBLE SHOOTING SKILLS TO IMPART TECHNICAL KNOWLEDGE, JH SUB COMMITTEE AND TPM SECRETARIAT SHOULD IDENTIFY VARIOUS TECHNICAL SUBJECTS IN CONSULTATION WITH OPERATION AND MAINTENANCE.

Slide 31: 

THE SUBJECTS COVERED ARE HYDRAULICS PNEUMATICS DRIVE SYSTEMS LUBRICATION COOLANT ELECTRICAL BOLTS AND NUTS

JISHU HOZEN - STEP 5(CONDUCT GENERAL INSPECTIONS AUTONOMOUSLY) : 

JISHU HOZEN - STEP 5(CONDUCT GENERAL INSPECTIONS AUTONOMOUSLY) In Jishu Hozen step – 5, an overall inspection process is formalized by combining tentative standards created in step 3 + additional check items for routine inspection. Thus, all inspection items for each area of equipment are split into two lists. i.e., one that can be handled by operators thro’ autonomous inspection and other that require inspection by maintenance. If any breakdown occurs, operator has to work with maintenance to develop inspection points that will prevent breakdowns of the same nature in future. Incorporate the above new inspection points into standards.

JISHU HOZEN - STEP 6(SET STANDARDS AND MANAGE THE WORKPLACE) : 

JISHU HOZEN - STEP 6(SET STANDARDS AND MANAGE THE WORKPLACE) The 6th step of Autonomous Maintenance is called the Maintenance Management, which means the “Standardization of operators activities”STEP 1-5 : Operators carry out CLRI and maintain basic conditions of equipment after thorough understanding.STEP 6 - : Operators go beyond equipment to other aspects related to his operation The surroundings of the equipment need to be changed using good house-keeping and visual controls.

Eg., Raw material for current variety and next variety, work in progress, setting tools ready for use : 

Eg., Raw material for current variety and next variety, work in progress, setting tools ready for use MUDA – WASTE MURA – INCONSISTENCY MURI - STRAIN Should be Eliminated

JISHU HOZEN - STEP 7(On going autonomous maintenance and advanced improvement activities) : 

JISHU HOZEN - STEP 7(On going autonomous maintenance and advanced improvement activities) From JH Step 1-6, the following changes occur : Equipment changes Operator changes Work place changes The following skills are acquired :

Slide 36: 

1. Ability to detect, correct and prevent equipment abnormalities Ability to detect causes of abnormalities Ability to understand relationship between equipment and quality Ability to understand the equipment functions and mechanisms Ability to predict problems in quality and detect their causes. JH Step – 7 : Others recognize operator's ability. The operator will be able to challenge any problem that may occur in his equipment. The operators become independent, skilled and confident and are expected to monitor their own work and implement improvements autonomously.

Kobetsu kaizen ( focused improvements) : 

Kobetsu kaizen ( focused improvements) OBJECTIVES Identify equipment losses Machine Material Man OEE Availability x Performance rate x Quality rate Eliminate/ Reduce through Kaizens Improve OEE Productivity Reduce Cost

Major losses that Impede Equipment Effectiveness : 

Major losses that Impede Equipment Effectiveness Losses are SIXTEEN LOSSES ARE Equipment failure Setup & Adjustment Tool change Start up Minor stoppage & idling Speed Defect & rework Shut down Raw material & utilities Operating motion Line organization Transportation Measuring & adjustment Yield Energy Die/Tool/Jig

OVERALL EQUIPMENT EFFECTIVENESS : 

OVERALL EQUIPMENT EFFECTIVENESS OEE = AVAILABITY X PERFORMANCE X QUALITY AVAILABILITY = NET OPERATING TIME/OPEARATING TIME PERFORMANCE = ACTUAL OUTPUT/EXPECTED OUTPUT IN NET OPERATING TIME QUALITY = ACTUAL QUALITY / ACTUAL OUTPUT

OEE : 

OEE LOADING TIME – DOWN TIME AVAILABILITY = PERFORMANCE RATE = STD. CYCLE TIME X NO. OF UNITS PROCESSED OPERATING TIME UNITS PROCESSED - DEFECTS RATE OF QUALITY PRODUCTS = UNITS PROCESSED LOADING TIME

PLANNED MAINTENANCE : 

PLANNED MAINTENANCE OBJECTIVES RECORD ALL MACHINE BREAK DOWN ANALYZE THRO’ WHY – WHY & PM ANALYSIS IMPLEMENT KAIZENS SCAN FOR HORIZONTAL DEPLOYMENT ACHIEVE ZERO BREAK DOWN SUSTAIN ZERO THRO’ PM/CLRI STANDARDS IMPLEMENT MTBF/ MTTR IMPROVEMENTS

QUALITY MAINTENANCE : 

QUALITY MAINTENANCE OBJECTIVES IDENTIFY DEFECTS CLASSIFY INTO A,B,C,POKA YOKE, INCOMING MATERIALS ELIMINATE THRO’ WHY – WHY & PM ANALYSIS ON 4M CONDITIONS AND POKA YOKE ACHIEVE ZERO DEFECT & SUSTAIN THRO’ WHY OK STANDARDS

TYPES OF DEFECTS : 

TYPES OF DEFECTS TYPE A TYPE B TYPE C POKA YOKE (MANUAL ERROR) INCOMING MATERIAL DEFECT

TYPES OF DEFECTS : 

TYPES OF DEFECTS A –TYPE DEFECT B –TYPE DEFECT C –TYPE DEFECT ACTION TAKEN BY OPERATOR NO ACTION BY OPERATOR ACTION TAKEN BY OPERATOR LSL : LOWER SPEC. LIMIT USL : UPPER SPEC.LIMIT

TOOL MANAGEMENT : 

TOOL MANAGEMENT OBJECTIVES IDENTIFY TOOL RELATED LOSSES SHORT LIFE TOOLS & HIGH COST TOOLS ANALYSIS & KAIZENS FOR LINE STOPPAGE REDUCTION DUE TO NOP TOOLS TOOL LIFE IMPROVE – MATERIAL /DESIGN CHANGE COST REDUCTION – TOOL BUYING AND INVENTORY ACHIEVE ZERO TOOL LOSS DEFECT & REDUCE TOOL COST

EDUCATION & TRAINING : 

EDUCATION & TRAINING OBJECTIVE ENHANCE KNOWLEDGE &SKILL OF OPERATORS MAINTENANCE PERSONNEL

OFFICE TPM : 

OFFICE TPM To improve productivity in offices Processing time loss Communication loss Accuracy loss Information retrieval time loss Goal Activity lead time reduction Inventory reduction Cost reduction

SHE : 

SHE Objective S – l zero accidents due to unsafe condition l zero accidents due to unsafe act l Identify maximum number of near misses H – zero occupational health decease E – conservation of natural resources reduce generation of waste no spillage and Clean factory and green

Development Management : 

Development Management Objectives Implement efficient product development and equipment investments Buy Equipments that are free from seven major losses

Slide 54: 

THANK YOU

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