Introduction

The Place (General Electric ENVS Aguascalientes)

A partir de Agosto de 2004 GE Energy, complet la adquisicin de BHA Group Holding, Inc., como parte de la expansin de General Electric en sus Servicios Ambientales.

La adquisicin permite a GE Energy expandirse significativamente en el rango de servicios ambientales que ofrece.

The Philosophy (TPM)

Total Productive Maintenance (TPM) A Japanese philosophy focused in keeping the machinery working in optimal conditions and eliminates wastes by:

Making equipment more efficient Conducting preventative, corrective and autonomous maintenance Mistake-proofing equipment Effectively managing safety and environmental issues.

Against the traditional thinking of I use the machine, you repair it, TPM involves all the workers in the cleaning and maintenance to reduce the failures and wastes. TPM is based in 8 pillars, where the most basic is the implementation of the 5S philosophy.

In this project only 4 of the pillars will be used: 5S Planned maintenance Training Autonomous maintenance Looking for the achievement of the next objectives: Reduction of the downtime mean Reduction of the failure frequency Maximization of the machinery productivity Reduction of maintenance cost More capable and effective workers

The project (TPM implementation in FF and GTIS)

The project consist in the implementation of the TPM philosophy in the most important production areas of the factory: Fabric Filter and GTIS The general objectives are: Reduction of the downtime mean Reduction of the failure frequency Maximization of the machinery productivity Reduction of maintenance cost More capable and effective workers Improve the workplace Increase safety

Needs identification
An analysis of the data was made in order to be more effective and focus the efforts in the main problems in the plant that TPM could solve. The failure reports of the past 6 months showed to us: The type of machines with more failure frequency The critical failures The maintenance tasks that increased the down time and their duration The machines with more failures (critical machines)

Charts
1.1.1 Failure type frequency

Current situation
1.1.2 Failure frequency by machine type

1.1.3 Most problematic machines by failures

QUANTIT MACHINE Y 155 30 105 28 237 67

242 35 5

65 45 44

1.2 Results
As a result of the analysis we could identify that the critical type of machines and the most problematic of them were:

MACHINE TYPE 7A 7C Tuber Machine

And the critical failures were: Broken thread Out of time It jumps

MACHIN E 155 105 237 242 35 5

Piece damaged, loose or missing Slides

Threaded

Objectives

Defying Solutions

Planning
Because of the short period of time available (8 weeks) TPM cant be fully standardized in the whole process, these would need from 2 to 5 years. So only 4 of the 8 TPM pillars were chosen: 5S Planned maintenance Training Autonomous maintenance They were chosen because of their importance and the fact that some of them have already been used in some grade. The next metrics were established to measure the improvement rate in the project: Down time mean Failure frequency Number of machines standardized in Autonomous maintenance Percentage of standards accomplishment Percentage of workers trained

Standardization

Implementation

Control

Continuous improvement