The Lean Enterprise 09_Intro_to_TPM_31_pgs(全员设备预防维护)

Measure
Availability
Formula =
460 min – 60 min
460 The Theoretical Cycle
Metric
2. Set-up & adjustments
] ] ]
Load – Down Time x 100% Load Time
example:
= 87%
3. Idling and minor stoppages 4. Reduced speed
Identifies Design weaknesses and improves the equipment to error-free function (via poka-yoke) Improves technical maintenance skills for checks, inspections, and overhauls
Efficiency
=
Time x Processed Qty
x 100% = 50%
Operating Time
example:
0.5/ unit x 400 units 400 minutes
5. Defects in Process 6. Reduced Yield
Ratio of Quality Products example:



TPM – The Need

Process Industry relies heavily on equipment that is integrated and runs continuously When down, losses are costly With lower inventories, machines need to be reliable Machining and Assembly industries becoming more mechanized to save manpower and do difficult jobs – More machines to maintain – Need to save energy

Total Maintenance
– Involves the whole maintenance system inclusive of equipment manufacturer, equipment engineering, and equipment user to improve maintainability


TPM – Operational Goals, cont. (Quantitative)

Safety – Zero accidents

Quality – Zero failures – Zero complaints

Education – Hours of training/ number of sessions – Number of KAIZEN projects – Number of Suggestions

TPM – Role of Maintenance Function

Provides technical support for autonomous maintenance done by operators


Restores deteriorated equipment through checks, inspections, and overhauls
After
> 90% > 95% > 99% > 85%

TPM – Operational Goals (Qualitative)

Increase number of suggestions Improve level of teamwork of shop floor Improve cross-functional teamwork Establish maintenance throughout the total equipment life cycle People maintain their own equipment Machines available for just-in-time (JIT) application Improve machine availability Improve working environment (6S) Improve Corporate culture and image Improve Business performance
Material Losses
– Losses in yield due to „inherent waste‟ (cut-off stock, set-up pieces, prototype, etc) – Energy losses such as electricity, gas, and water when machinery is not doing valueadded work – Idling losses due to inadequate sensors and product buildup on conveyors and chutes

TPM – Role of Operator Function

Maintains basic condition (cleaning and lubrication) Maintains proper condition and standards for equipment usage Partially restores deterioration Basic skill levels in: – Changeover and set-up – Reduction of minor stoppages and adjustments
The Lean Enterprise
Introduction to TPM – Total Productive Maintenance
Lean Foundations Continuous Improvement Training
Learning Objectives

Learn the basic philosophy of TPM Explain OEE and how it contributes to a TPM project, explore OEE components; define and calculate OEE List 6 major components of equipment loss Review and adopt the 7 steps to Autonomous Maintenance
Yield (Quality)
TPM attacks 6 major “Losses” plus Elimination of other Wastes (Mura, Muri, Muda)
Operator Time Losses
– Manpower losses due to operation time being done more slowly than standard time (Cycle Time > Standard Time)
Total Participation
– – – – – Everyone has a role to make TPM work Management to set policy Middle management, staff to support and lead Maintenance to maintain and train Operators to take on new maintenance challenges

TPM – Definition of „Total‟

Total Effectiveness
– Reduction in losses of all equipment to optimize its effectiveness and improve costs

TPM – The Philosophy

TPM aims at using equipment to its maximum and aids in reducing Life Cycle Costs (LCC) In other words - going all out to eliminate the Losses (Waste) caused by the equipment TPM improves work activities that deal with Equipment Set-up, Operating parameters, Maintenance, Tear down, Repairs and Breakdowns It specifically aims at the complete elimination of the „six major losses‟ while striving for a goal of zero unscheduled downtime
=
Processed Amount – Amount of Defects Processed Amount 400 – 8 400
x 100% = 98%
Overall Equip. Effectiveness:
.87 x .50 46.2 % .98 =
OEE Pareto Analysis by Loss Category

Best Practices World-Class Goals (A TPM “Vision”)