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✔ Intangible effects
➨ My Machine concept - First - Line operator owns the
➨ equipment
➨ Concept of Zero
➨ Clean Workplace
operators
environment i.e.
➨ Cost related
✔ Equipment Efficiency
Availability Related
1 Break Down loss 2 Setup loss
3 Tool change loss 4 Start up loss
5 Planned Maintenance
Performance Related
6 Minor stops
7 Reduced speed
Defect Related
8a Scrap
8b Rework
✔ Human efficiency
9 Management Losses
10 Operating motion Loss
11 Line Organization loss
12 Loss due to failure to automate
13 Loss due to Adjustment & Measurement
✔ Cost Related
14 Yield Loss
15 Energy Loss
16 Die/Tool loss
TPM - 12 Step Approach 7
Overall Equipment Effectiveness
Defect losses
➨ Phase 2 - Launch
➨ Phase 3 - Execution
➨ Phase 4 - Establish
department
of activity
✔Tools focus is on
Formation of circles
Allocate areas to each circle
Training to all Circle
members
Start 1S,2S movement
Start Pick up movement
Change to ‘’No drop’’
movement
Maintain shop floor neat &
clean
Sustain
TPM - 12 Step Approach 24
Jishu Hozen
✔ Step 1
➨ Discover by cleaning
lubrication is difficult
➨ Audit by Unit Head
✔ Step 2
➨ Eliminate source generating dirt/dust oil etc.
➨ Improve the places of hard to access for cleaning,
lubricating and inspection to shorten the time required
for the above
✔ Passing of the audit
➨ Cleaning / inspection / lubrication time reduction
➨ Break down reduced by 50 %
➨ Machine clean without cleaning
✔ Planned Maintenance
➨ Achieve Zero breakdown
➨ Focus is on addressing natural deterioration
➨ Supports JH to tackle forced deterioration
➨ Aims at drastic reduction in Repair & Maintenance Cost by
➨ improving service life of parts and reducing time to repair
✔ Step 8: MP activity
Maintenance Improvement
activities activities
MAINTENANCE PREVENTION
Daily Jishu Hozen
equipment
➨ To establish system for ensuring reliability, maintainability
✔ Step 1
➨ Gap analysis
➨ Stratification
✔ Step 2
➨ Develop QA matrix
✔ Step 3
➨ Identify 4 M conditions
✔ Step 4
➨ Defect classification (a/b/c type)
➨ Why Why analysis
➨ PM analysis
TPM - 12 Step Approach 38
Methodology
✔ Step 5
➨ Implement Poka yoke/ kaizen / countermeasures
➨ Set 4 M conditions
➨ Derive Q components
✔ Step 6
➨ Prepare cause side checklist
✔ Step 8
➨ Standard operating procedure
✔ Step 9
➨ Provide specific training to engineers / machine operators
TPM - 12 Step Approach 39
Step 10 - Improvement in Indirect Departments
➨ Job elimination
➨ Job clubbing
➨ layout changes
➨ Reduction in mudas
Leading to
Commitment of all
Involvement of workforce
Happy and Motivated employees
Ready to face challenges &
Satisfy changing customer needs
TPM - 12 Step Approach 44
Step 12 - PM award qualification examination