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Finishing TPM Kaizen Clean Sweeps

Nonproprietary

Hayes Lemmerz International, Inc.


Gainesville Operations
NONPROPRIETARY DOCUMENT 1

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Team Name: Clean Sweeps Customers: Final Inspection

Describe the Problem


Project Start Date: 3-21-07

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

Describe the Problem TPM

TOTAL PRODUCTIVE MAINTENANCE

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
NONPROPRIETARY DOCUMENT 3

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45 40 35 30 25 20 15 10 5 0 12-Feb

Analyze Historic Results/ Map Current Process

TOTAL TPM

19-Feb

26-Feb Due Complete

5-Mar

12-Mar

NONPROPRIETARY DOCUMENT

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PRETREAT TPM
12 10 8 6 4 2 0 12-Feb 19-Feb 26-Feb Due

Analyze Historic Results/ Map Current Process

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

NONPROPRIETARY DOCUMENT

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LIQUID TPM
9 8 7 6 5 4 3 2 1 0 12-Feb 19-Feb 26-Feb Due Complete

Analyze Historic Results/ Map Current Process

5-Mar

12-Mar

CLEARCOAT TPM
14 12 10 8 6 4 2 0

NONPROPRIETARY DOCUMENT

12-Feb

19-Feb

26-Feb Due Complete

5-Mar

12-Mar

Analyze Historic Results/ Map Current Process

NONPROPRIETARY DOCUMENT

Identify & Prioritize Waste

Check Marks = Completed Circled = Not Completed

NONPROPRIETARY DOCUMENT

Root Cause/ 4 Evaluate Identify Improvement Needs


TPM FINISH - KAIZEN
Material Personnel

Manning shortages

Lack of tools to perform PMs

Lack of priorities

Lack of ownership by areas

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

TPM not C ompleted on Time

Env ironment

Methods

Machines

NONPROPRIETARY DOCUMENT

Activities/ 5A Document Containment


What
Write Charter for team Review present paint TPMs Review and write TPM procedures TPM procedures for Pretreatment TPM procedures for Primer TPM procedures for Liquid TPM procedures for Clear Revise Weekly PM List Routzahn Team Team Lan, Gustova, Dustin Ribbit, Samantha, Jeff Ribbit, Samantha, Jeff Ribbit, Samantha, Jeff Routzahn

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

NONPROPRIETARY DOCUMENT

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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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Review Performance

PM completion will be tracked on a monthly basis.

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PERFORMED DATE: PLANT

Implement Controls/ Standardize


FOCUS FACTORY LINE MACHINE NAME

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

DUMP AND CLEAN THE TANK

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

Per dump Schedule

TRANSFER SOLUTION AND CLEAN THE TANK

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

Per dump Schedule

DUMP AND CLEAN THE TANK

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

Per dump Schedule

13
270
Minutes

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