Stability Tools TPM

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Stability Tools TPM
What is TPM ? TPM stands for Total Productive
Maintenance and covers two main types. Planned
Maintenance- Major activities carried out by
the plant maintenance team at set intervals to
prevent known failure conditions from
occurring. Autonomous Maintenance- Minor
maintenance activities such as checking,
lubrication and minor adjustments. All tasks
carried out by the operators in their cell. Why
do we need TPM ? Using TPM enables us to monitor
our equipment and escalate concerns prior to
failure. It encourages ownership through
learning, as each operator is trained in the
maintenance requirements for their particular
process. TPMs main objectives are to ensure a
quality product is produced repeatedly, and at
the required volumes with the correct level of
investment.

• Planned Maintenance Tools
• There are three main tools required to ensure
  that we have a robust Planned Maintenance System,
  and they are-
• Detailed Standards of how to carry out
  maintenance activities. These standards will
  usually be supplied by the Equipment manufacturer
  and held in a known location for reference, or
  will be written by the maintenance department
  using the Standard Work Format, where manuals are
  not available.
• Visual System to show which tasks are due and
  when, and a reference document to show who is the
  best resource to achieve a timely completion.
  This type of visual system is known as
  Kamishibai which translated means Story by
  Cards.
• A predictive system which relies on the inputs of
  those persons carrying out the checks to ensure
  relevant information is produced. This system
  analyses breakdowns by equipment type and failure
  mode. The system then informs the maintenance
  department of the required frequency with which
  to carry out specific tasks.

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Stability Tools TPM - Cont
What Does the Visual System Look Like ? Each
planned maintenance task is transferred to a
T-card. On this card is the following detail-
Spares Tooling Requirements Which spare parts
or tooling are required to carry out the task
successfully. This can also be linked to the
predictive database and x-references with the
stock levels to ensure all spare parts are or
will be available and that all tooling will be in
a serviceable condition for the due date of the
check. Repair Manual Location The repair manual
will normally be the product manual supplied to
the maintenance department by the Original
Equipment Manufacturer (OEM). If there is no
written standard from the OEM then a set of
Standardised work documentation will be written
by the Maintenance department. This documentation
will detail how the task should be carried out
using work element sheets to support. The
reverse side of the card is similar to the front
red side except for its colour which is green and
an area detailing the next due date for the check
and who carried out the last check.
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Task Description Exactly what the equipment is
and what is to be checked. Card No Each card is
individually numbered and is used when frequency
updates are flagged by the predictive computer
system. Frequency How often the check should be
carried out to prevent failure.
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Stability Tools TPM - Cont
Visual Display of Work Cards
Every time a work task is completed by an
operator the card should be turned over to
display the green side of the card. This then
highlights at a glance which tasks remain
unfinished. Each column is reviewed by the
maintenance manager at the end of the working
week. All cards which remain RED are interrogated
as to why the work was not carried out as
planned. All Green cards are then reviewed for
their next due date, in 1 week to 1 year. The
card is then moved to its next due dated slot and
turned to the Red side to show that it is a due
task. The board should never display a Green
card in any other week than the current working
week. Blue cards are for outside contractors and
should only be displayed for planned repetitive
maintenance activities. The reverse of this card
is again green to highlight completion. The Blue
cards are usually placed against supervisory
positions, this is mainly for performance
tracking purposes.
How the visual display system works Each column
of the visual display board represents a one week
period. Each row of five slots across the board
represents an individual maintenance technicians
workload. The work cards are usually distributed
by skill set, electrical, mechanical, hydraulics
etc. These skill sets are visually managed by the
use of a core skill versatility matrix which
should be displayed next to the work card board.
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Stability Tools TPM - Cont
What Does Autonomous Maintenance Mean
What do the sheets look like ?
The definition of Autonomous is Self Reliant.
Therefore this level of maintenance focuses on
the owner or user of a piece of equipment to
monitor and conduct basic maintenance tasks. This
aim of this Element of TPM is to reduce minor
stoppages and to give advanced warning of known
failure types thus reducing product defects and
equipment downtime. The checks and maintenance
tasks which are to be carried out by operators
are simple but important. Failure to execute
these checks regularly can and will result in
preventable downtime. The checks are designed by
the maintenance department based upon their
current knowledge of regular concerns and their
occurrence frequency. All checks are recorded on
a common TPM schedule for the area and signed off
as completed at the end of shift.
Maintenance Check Sheet The detailed check sheets
are placed in the back of each standardised work
process folder. This ensures that as part of the
operators standard training all TPM checks are
covered and understood.
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Each check has a photograph or drawing of the
piece of equipment to be checked, with numbered
arrows pointing to each check area and
corresponding to the numbered check item detail
on the right hand side of the sheet. Each
detailed check item then has its frequency placed
in the far right hand column.
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Stability Tools TPM - Cont
TPM Check Schedule The schedule covers each check
to be carried out over a one month period by the
entire team. Obviously this depends upon the size
of the team. When the team leader to operator
ratio of 15 18 has been exceeded then more
than one schedule may be required.
Green Ok no problems can be seen or task has
been carried out successfully. Orange An issue
has been found whilst carrying out a check. This
issue will not cause imminent failure or a
stoppage but if not addressed within the next day
could result in equipment downtime. Red A
critical failure was highlighted and maintenance
were called immediately. At the end of each
shift the team leader signs off on all checks to
ensure that they have all been carried out as
planned. These documents are handed back to
maintenance at the end of each month for data
collection, and the new sheet is placed at the
team board or on the relevant piece of
equipment. New or re-occurring problems are dealt
with via the problem and countermeasure meeting
to help reduce or eliminate the problem or its
effects.
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As each check is carried out at the desired
frequency then the circle corresponding to that
check is coloured in one of the following colours.
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Stability Tools TPM - Cont
The maintenance manager then conducts a weekly
walk of all production areas to review
maintenance issues with all areas. During these
walks all visible red tags will be reviewed as to
their date of placement. Any tags which have not
been addressed, which means work is in progress
or completed, will be escalated at the next
maintenance shift handover meeting. The outcome
of this meeting will be fed back immediately to
the team leader.
TPM Tag System The Tag system has been developed
to enable communication on non critical issues.
The Tag is supplied in one piece and is
perforated through the middle. The top half and
bottom half of the tag hold duplicate information
and are completed by the team leader on
notification of an orange mark on the schedule or
via an Andon call from an operator. The top half
of the Tag is tied with a piece of chord to the
piece of equipment with the concern. The tag must
be tied as close as is feasibly possible to the
failing area so as to act as a visual guide to
the assigned maintenance operator. The bottom
half of the Tag is then torn off and taken to the
maintenance post box at the end of the
shift. Maintenance review the post box at the
start of the next shift and assign the Tags to a
technician with the relevant skill sets to carry
out the task to the required standard. Once the
task has been completed successfully the Top half
of the Tag is removed and signed off by both
technician and the Team leader for that area.
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