Total Productive Maintenance

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Total Productive Maintenance
Manufacturing ????
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Total Productive Maintenance ACE Manufacturing
Qualifying Level
6S
QCPC
Market Feedback Analysis
Set-Up Reduction
Root Cause / Corrective Action
Standard Work

Mistake Proofing
Process Certification
Quality Clinic Activity
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??????? ACE ????????
6S
????? ??
?????? ??
???? ??
???? ??
???? ????
??? ??

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???? ??
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TPM ???????

• Total Productive Maintenance is an equipment
  management strategy that improves equipment
  efficiency.
• ????????????????????????
• Or, in other words...
• Treating the equipment
• like it is your own!
• ??,????.
• ????????????
• ??!

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TPM Key Concept TPM?????

• Left neglected... Equipment Breaks Down
• ????????????

In the past, maintenance focusedon fixing
equipment after it broke. ??,????????????? ???????
??
TPMs focus is to prevent problems before
equipment breaks. TPM ????????????????????
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Total Productive Maintenance is a New Way of
Working?????????????????

• Old Attitude
• ?????
• I operate, you fix.
• ???,????
• I fix, you design.
• ???,????
• I design, you operate.
• ???,????

• TPM Attitude
• TPM??
• We are all responsible for our equipment.
• ??????????????

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Tip of the Iceberg?????
A failure is just the tip of the
iceberg! ???????????!
Failures ??
Hidden Defects ?????
Wear, play, slackness, leakage, dust, dirt,
corrosion, deformation, adherence of raw
materials,surface damage, cracking, overheating,
vibration, noise, and other abnormalities. ???????
????????????????????????????????????????????
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Typical Causes of Machine Breakdown ?????????
Grit and chips in revolving or sliding
parts ??????????????
Contamination of sensors, contacts and
Connectors ???????? ?????
I wonder whats going to fail next? ?????????? ???
?
Dirt and dust on cooling fan ?????? ?????
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TPM Techniques TPM??

• Simplify and Document TPM Activities.
• ?????TPM??
• Use visual techniques to indicate
• whats right / whats wrong.
• ????????????
• ??/??????
• PM Completed? ??????????
• Pressure gage ???
• Sight glass ??
• Arrows for motor rotation
• and fluid circulation???????????
• markings for spare parts and fluids.
• ??????????
• Making PM devices more accessible.
• ?????????????
• Filters, fittings made more accessible ????????
• Transparent panels to facilitate inspection
  ????????????

Normal operating Range ??????
Danger! ??!
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TPM Benefits TPM???

• Reduced maintenance costs
• ??????
• Breakdown maintenance is 10 times more costly
  than planned maintenance
• ?????????????????10???
• Enhanced safety ?????
• Find exposed wires, open belts, missing guards,
  loose hardware
• ???????????????????????????
• Reduced waste ????
• Prevents loss of lubricant, compressed air
• ?????????????
• Improved quality ????
• Equipment more capable of holding tolerance
• ??????
• Less down time, longer life??????,????

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12 TPM Qualifying Activities
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12 ?TPM ????
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Lockout/Tagout Review ??/????
PURPOSE of Lockout/Tagout ??/?????
To prevent you or someone else from inadvertently
turning a power source on and causing a potential
injury or even death. ????????????????????????
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Lockout Device ????
Lockout/Tagout Review ??/????
A lock or other device that utilizes a positive
means, to hold an energy isolating device in a
safe position and thereby preventing the
energizing of a machine or piece of
equipment. ????????,???????????????????,??????????
?????
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Tagout Definition ?????
Lockout/Tagout Review ??/????

• The process of securely fastening a tag or
  prominent
• warning sign to indicate that both the energy
  isolating
• device and the equipment being controlled, must
  not be
• operated.
• ???????????????????
• ???????????????????
• ???????
• The tag will also include the name
• of the person who locked out
• the equipment.
• ???????????
• ?????

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WARNING ??
Lockout/Tagout Review ??/????

• NEVER ACCEPT LOCKOUTS KEYS FROM ANYONE.
• ?????????????????
• THE ASSOCIATE RESPONSIBLE FOR APPLYING THE LOCK
  OR TAG IS THE ONLY PERSON AUTHORIZED TO REMOVE
  THE LOCK OR TAG.
• ??????????????????????????

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ACTION ITEM 1 Assess All Equipment????1??????

• By Equipment we mean any machine that was a
  capital expense and has a depreciative value. Or
  any machine that is important to your cell.
• ???????????????????????????????????
• We Categorize all Equipment based on how Unique
  and Critical it is to ensure we focus attention
  on the right equipment first. Pay special
  attention to bottleneck equipment.
• ???????????????????????,??????????????????????????
  ???????

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ACTION ITEM 1 Assess All Equipment
(cont.)????1??????(??)

• Category A Critical equipment for which an
  alternate machine is not feasible, because
• A???????????????,??
• No alternate exists, or
• ?????,?
• The alternate is usually unavailable due to
  utilization, or
• ????????????????,?
• It would be too costly/time consuming to
  transition to the alternate
• ??/??????????
• Category C Equipment for which it is relatively
  easy to find a replacement or alternate
• C???????????????
• Includes most off-the-shelf equipment
• ????????
• Typically cost lt 2,500
• ????2,500
• Standard spare parts (like drive motors) are
  available off-the-shelf
• ??????????(?????)
• Category B All other equipment/machines
• B???????/??

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ACTION ITEM 1 Assess All Equipment
(cont.)????1??????(??)

• In addition to machine category, create a table
  listing all machines and additional categories,
  such as
• ??????,?????????????????,?
• Year of manufacture
• ???????
• Type of machine? Condition? (Good / Fair / Poor)
• ????????(?/??/?)
• Does Operator PM process exists (Has a service
  card been created?)
• ?????????????(???????)
• Does Maintenance PM process exist (Does a written
  maintenance task list exist?)
• ????????????(????????????)
• Has the machine undergone initial cleaning?
• ????????????
• Has machine been assessed for safeguarding per
  SP008? (EHS items)
• ??????????SP008???(EHS?)

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ACTION ITEM 1 Assess All Equipment
(cont.)????1??????(??)

• Possible Categories
• ?????
• Good Equipment which retains all of its
  original functions, accuracy and reliability.
• ????????????,??????
• Average Equipment which has lost some of its
  original functions or accuracy. Its output
  normally meets the required specifications.
• ??????????????????????????????
• Poor Equipment which is no longer accurate or
  reliable. In order to produce acceptable output,
  this equipment requires operator intervention
  well beyond the original level.
• ??????????????????????,????????????????????

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ACTION ITEM 2 Write Machine-Specific
Lockout Procedures

• Lockout procedures
• must be written and
• implemented for each
• machine
• General procedures are in
• effect for Sullair
• Procedures need to be
• written jointly with facilities
• maintenance

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???? 2 ????????????

• ??????????
• ????????
• ???????????
• ?????????
• ?????

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ACTION ITEM 3/4 Operator Walkaround and
PM Schedule on 100 A/B

• Operator PM defined for 100 of Category A and B
  machines
• A book or sheet exists which defines the
  daily/weekly/monthly Operator PM tasks
• Include safety equipment operation (guards, limit
  switches, etc.) in Operator PM.
• Operator PM conducted faithfully (1 month prior
  to audit) on all Equipment for which it is
  defined.

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???? 3/4 ?????? ??
A/B????PM???

• ???PM?????A?B???
• ??????????/?/??PM??????
• ??????(??????????)
• ?????????????????????(???????)

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ACTION ITEM 3/4 Operator Walk around and
PM Schedule on 100 A/B

(cont.)

• Make Operator PM effective
• Use a Visible at-a-glance system (Such as a
  color-coded PM Status board) within the cell to
  indicate the actual status of Operator PM
  tasks.
• Must be easy to understand
• No book or folder to read

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???? 3/4 ?????? ??
A/B????PM???(??)

• ??????????????
• ??????????? (???????PM???) ?????????PM???????
• ??????
• ????????

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ACTION ITEM 5 Initial Inspect/Clean 100
A/B???? 5????/????A/B???
You clean to improve a machines performance -
not its appearance ???????????- ?????
Clean to Inspect ????? Inspect to
Detect ????? Detect to Correct ?????
Cosmetic Cleaning ?????
You get a better looking piece of equipment as a
benefit but not as the only objective ????????????
,?????????
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ACTION ITEM 5 Initial Inspect/Cleaning 100 A/B
(Cont.)???? 5????/????A/B???(??)

• Accessible components cleaned, inspected and
  repaired
• ??????????????
• PM documentation is reviewed/updated
• PM?????/??
• Basic improvements are incorporated to improve
  maintainability and visual
• ????????????????
• operating condition
• ????

How about that. I didnt even know there was
a grease fitting here! ?????????? ????????? ??!
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ACTION ITEM 6 Track Downtime History????
6????????

• Maintenance Downtime is the time a machine is
  down for maintenance purposes
• ????????????????
• ???
• Unplanned ????
• Breakdowns and Repairs
• ?????
• Planned ????
• Operator PM ???PM
• Maintenance PM ??PM
• Maintenance Downtime Goal
• ??????
• Reduce Breakdowns and Repairs
• ???????

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ACTION ITEM 7 Top Ten Downtime???? 7??????

• Use downtime tracking results
• to determine the top ten
• downtime equipment.
• ???????????
• ??????

Pareto Chart Pareto ??
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What is next????????
Complete TPM training of your work group by
March 7, 2001 2001?3?7???????? ??TPM??
Before the end of February, look for a
groupwise announcement of a Drivers Meeting to
discuss the necessary resources and logistics for
completing qualifying TPM activities ?2????,?????
????, ??????????????? ???????TPM??
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Summary ??

• We want a company that reveres people who
  design, build and maintain things that never
  break, rather than people who fix things that
  break.
• George David
• UTC Chairman and CEO
• ?????????????????????
• ??????,????????????????
• 
  George David
• UTC Chairman and CEO

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Total Productive Maintenance???????
Manufacturing???