tpm-catalyst

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Decision making alternatives Non decision Autocratic Minority Majority ( voting ) Consensus (motivational approach – TQM) Logical problem solving – TPM (for every phenomenon there is a cause) Why TPM? Catalyst Why What

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What Is TPM It Is Total Profit Management Total People Management Total Perfect Manufacturing Total Productive Maintenance Why What !

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L Length Stages

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Four Phases of Training 1 : Do not know. 2 : Know the theory but cannot do. 3 : Can do but cannot teach 4 : Can do and also teach. Stages History Problem Effect Productive Maint Aim How Eight Pillars Focus Combination OEE

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History of TPM Innovative Japanese concept. The origin of TPM –Preventive Maint First company : Nippon denso PM introduced in Japan From USA plant wide preventive maintenance *Preventive maintenance* Operators for prodn & Dedicated team for maint. Stages History Problem Effect Productive Maint Aim How Eight Pillars Focus Combination OEE

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( This is Autonomous maintenance, one of the features of TPM ) Due to automation of Nippondenso Manpower required for Maint. It was decided that the routine maint. of equipment by the operators. Maintenance group took up only essential maintenance works. Maint. became a problem Stages History Problem & Action Effect Productive Maint Aim How Eight Pillars Focus Combination OEE

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The modifications incorporated in new equipment Maintenance Prevention. This Change Leads to Equipment Modification Stages History Problem Effect Productive Maint Aim How Eight Pillars Focus Combination OEE

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Productive Maintenance. Maintenance prevention + preventive maintenance Stages History Problem Effect Productive Maint Aim How Eight Pillars Focus Combination OEE 9 Star

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Below are nine dots arranged in a set of three rows. Your challenge is to draw four straight lines which go through the middle of all of the dots without taking the pencil off the paper. you must start from any position and draw the lines one after the other without taking your pencil off the page. Each line starts where the last line finishes .

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1 2 3 4

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Lessons to be learned from this puzzle Look beyond the current definition of the problem Hard work is not the solution Repeating the same wrong process again and again with more vigour does not work. You can be very close to a solution while not getting any closer to it. Thought is the solution, physical hard work will not work Aim

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maximize plant and equipment effectiveness Stages History Problem Effect Productive Maint Aim How Eight Pillars Focus Combination OEE

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Nippon Denso had made Quality Circles, involving the employees participation. Thus all employees took part in implementing Productive maintenance This is TPM It is path to long term continuous improvement rather than the promise of a quick fix Stages History Problem Effect Productive Maint Aim How Eight Pillars Focus Combination Main tech OEE

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Autonomous Maintenance Planned Maintenance Quality Maintenance Training Safety Health & Environment Kaizen OFFICE TPM TPM 5S OEE OEE OEE Stages History Problem Effect Productive Maint Aim How Eight Pillars & Output Focus Combination OEE 5S 5S 5S 5S 5S 5S

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Focus of Training Focus on improvement of knowledge, skills and techniques. Creating a training environment for self learning based on felt needs. Training to remove employee fatigue and make work enjoyable. 5'S' Kaizen Autonomous Maint. Planned Maint. Quality Maint. Office TPM S H E Stages History Problem Effect Productive Maint Aim How Eight Pillars Focus Combination maint tech OEE

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Stages History Problem Effect Productive Maint Aim How Eight Pillars Focus Combination main tech OEE Word class Corrective – Maintenance on failure Preventive – Scheduled maintenance Predictive – Based on Observation Detective – Based on regular checks TPM uses a combination of four maintenance techniques WITH TOTAL INVOLVEMENT OF OPERATORS & MAINT. TEAM

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(Total processed products – Total rejected products) (Total processed products) OEE= Availability (A) x Performance (P) x Yield (Y) (Planned production time - Unscheduled Downtime) Planned production time A = Cycle time x number of products processed Production time P = Production time = Planned production time - Downtime Q = Stages History Problem Effect Productive Maint Aim How Eight Pillars Focus Combination OEE World Class Quality ( Q)

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OEE = Availability x Performance x Quality Worldwide studies indicate that the average OEE rate in manufacturing plants is 60%. Stages History Problem Effect Productive Maint Aim How Eight Pillars Focus Combination OEE World Class Data Collection A World Class OEE is considered to be 85% or better Farmers Math

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One Farmer Purchases pair of Cow for Rs.1000.00 He sold same pair of Cow for Rs. 2000.00 He Purchases same pair of Cow for Rs. 3000.00 He sold same pair of Cow for Rs. 4000.00 A Profit how much ? B Loss how much ? C No Loss No Profit

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Planned Production Time = [Shift Length - Breaks]= [480 - 60]= 420 minutesOperating Time= [Planned Production Time - Down Time]= [420 - 47]= 373 minutesGood Pieces= [Total Pieces - Reject Pieces]= [19,271 - 423]= 18,848 pieces Stages History Problem Effect Productive Maint Aim How Eight Pillars Focus Combination OEE World Class Data collection Calculation

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Stages History Problem Effect Productive Maint Aim How Eight Pillars Focus Combination OEE World Class Data Collection Calculation Thks

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