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1
Team Name: Clean Sweeps Customers: Final Inspection
Team Members: Samantha Turner, Dustin White, Gustavo #1 Menchacu, Bob Ribbit Kohler, and Lan Nguyen.
Problem Statement: The finishing area has many production related TPMs set-up for maintaining equipment, dumping tanks, and general cleaning of the paint system. Adherence to this program has been very difficult to maintain and the TPMs that are required have not been completely documented as to what needs done, how to do it, and the time required to do each TPM. We also have no operating instructions that spell out what clothing should be worn during Paint Tech TPMs and system cleaning TPMs. When TPMs are not completed, rework and scrap increase for dirt and paint application issues, including paint drips, heavy clear and primer, etc. PM compliance has averaged 46% in the last 4 weeks since we began painting again on 3rd shift. Team Objectives: The objective of this team will be to analyze each TPM to verify that it is a value added TPM, write-up a description of this TPM, how often this TPM must be completed, the time required to complete each TPM, what PPE is required to be worn, and to review for other TPMs that might be value added but have not yet identified. Compliance to TPMs schedule is 100% obtainable each and every week. Metrics: % TPMs Completed for pretreatment, primer, liquid and clear coat systems. Input Boundary: Machining Expected Completion Date: 3-22-07 Approvals: Team Leader: Jeff Routzahn Output Boundary: Final Inspection Actual Completion Date: Team Champion / Sponsor: Rafael Alvarez
NONPROPRIETARY DOCUMENT
A systematic approach utilizing all employees through the implementation of team based activities to achieve maximum equipment effectiveness by reducing operating costs. Goals of TPM: Zero accidents Zero defects Zero breakdowns
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2
45 40 35 30 25 20 15 10 5 0 12-Feb
TOTAL TPM
19-Feb
5-Mar
12-Mar
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2
PRETREAT TPM
12 10 8 6 4 2 0 12-Feb 19-Feb 26-Feb Due
5-Mar
12-Mar
Complete
PRIMER TPM
12 10 8 6 4 2 0 12-Feb 19-Feb 26-Feb Due Complete 5-Mar 12-Mar
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2
LIQUID TPM
9 8 7 6 5 4 3 2 1 0 12-Feb 19-Feb 26-Feb Due Complete
5-Mar
12-Mar
CLEARCOAT TPM
14 12 10 8 6 4 2 0
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12-Feb
19-Feb
5-Mar
12-Mar
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Manning shortages
Lack of priorities
Not clear direction when facing a downtime situation Weekly tasks confused with daily tasks Lack of clear instructions Dirty environment Lack of planning High production demand Firefigthing instead of preventing Constant Machine breakdowns Unplanned downtime
Env ironment
Methods
Machines
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Who
When
3-21-07 3-22-07 3-22-07 3-23-07 3-22-07 3-23-07 3-23-07 3-27-07
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10
5B Identify Countermeasures
Post revised Weekly TPM Sheet Post new instructions in correct areas Instruct operators Routzahn Routzahn Turner 3-26 3-26 3-28
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11
Review Performance
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12
7
PERFORMED DATE: PLANT
GAINESVILLE
PERFORMED BY: REVISION DATE
FINISHING
AUTHOR
PRE-TREAT #2
REVISED BY:
Stage 1 to 3
APPROVED BY: PAGES
23-Mar-07
NOTES:
KAIZEN TEAM
St2 St3 St4 St5
E. REESE
FILL OUT MAINTENANCE WORK ORDERS FOR ANY ACTION NEEDED THAT YOU CANNOT COMPLETE YOURSELF. Work Order #:
St1
St6
Blow off Housing
St11
TPM COMPONENT Initials No. LOCATION
St10
St9
St8
NORM
St7
METHOD TOOLS TIME FREQUENCY
STAGE 1
TANK MUST BE CLEANED INSIDE AND OUTSIDE, FREE OF SLUDGE AND WHEELS
1. Verify that hangers are removed from the entrance to the end of tank 3. 2. Power off and LOTO main line conveyor and pumps. 3. Remove and clean filter with hose. 4. Remove wheels, sludge and debris 5. Cover entrance with tarp 6. Clean inside tank using brush and power wash machine and vacuum 7. Rinse off using hose. 8. Wipe off top, outside surfaces of tank using clean rags.
PPE - Watertide suit PPE - Rubber gloves PPE - Safety Goggles PPE - Rubber boots Cover tarp for entrance Bucket Hose Power wash machine Vacuum cleaner Clean Rags
120
STAGE 2
TANK MUST BE CLEANED INSIDE AND OUTSIDE, FREE OF SLUDGE AND WHEELS
(MAKE SURE STAGE 1 HAS BEEN CLEANED AND DUMPED PRIOR TO DUMP STAGE 2 BECAUSE CLEANER SOLUTION OF STAGE 2 MUST BE RE-USED IN STAGE 1.) 1. Verify that hangers are removed from the entrance to the end of tank 3. 2. Power off and LOTO main line conveyor and pumps. 3. Pump the solution from Stage 2 to stage 1 using pump. 3. Remove and clean filter with hose. 4. Remove wheels, sludge and debris 5. Clean inside tank using brush and power wash machine and vacuum 6. Rinse off using hose. 7. Wipe off top, outside surfaces of tank using clean rags.
PPE - Watertide suit PPE - Rubber gloves PPE - Safety Goggles PPE - Rubber boots Pump Cover tarp for entrance Bucket Hose Power wash machine Vacuum cleaner Clean Rags
120
STAGE 3
TANK MUST BE CLEANED INSIDE AND OUTSIDE, FREE OF SLUDGE AND WHEELS
NONPROPRIETARY DOCUMENT
1. Verify that hangers are removed from the entrance to the end of tank 3. 2. Power off and LOTO main line conveyor and pumps. 3. Remove and clean filter with hose. 4. Remove wheels, sludge and debris 5. Clean inside tank using brush and power wash machine and vacuum 6. Rinse off using hose. 7. Wipe off top, outside surfaces of tank using clean rags.
PPE - Watertide suit PPE - Rubber gloves PPE - Safety Goggles PPE - Rubber boots Cover tope for entrance Bucket Hose Power wash machine ( With Small handle) Vacuum cleaner Clean Rags Total time required:
30
13
270
Minutes