Slide 1

Total Productive Maintenance

TPM
Overview

Dave Hoyte, CEO
JL French Corporation

Slide 2
TPM as a Lean Initiative
Competitive costs require
Spending control
Defect control
Downtime reduction

TPM = Total Productive Maintenance
Proactive (with all employees involved)
Preventive
Predictive
Planned

Slide 3
Why Change?

ACTIONS:
Reduce defectives / scrap
Reduction of lost production time
Lowest possible cost by reducing waste

Slide 4
Lean System
5S
Visual
Factory
T P M
Standardized
Work
Leadership by Example & Commitment
In-Station Process Control
Lean Measures
Employee Involvement & Mutual Respect
Pull system / flow production
Peak Performance
Variation reduction / Six Sigma
Continuous Waste Reduction
Rapid Changeover / Customer-driven lot size
Slide 5
7 Wastes
Transportation
Excess production
Added processes
Motion

Waiting
Inventory
Non-conformance (defectives)
Slide 6
Causes of Waste
Excess Manning
Poor layout and material presentation
Rework and extra processes
Inconsistent / inefficient work methods
Excess Downtime
Tooling condition
Unreliable equipment
Long changeovers
Incapable process
Defectives - Rework or Replace
Incapable processes or process not
compatible with customer expectations or
design spec (design for mfg)
Tooling condition
Operator methods and errors
Slide 7
Causes of Waste
Excess Manning
Poor layout and material presentation
Rework and extra processes
Inconsistent / inefficient work methods
Excess Downtime
Tooling condition
Unreliable equipment
Long changeovers
Incapable process
Defectives - Rework or Replace
Incapable processes or process not
compatible with customer expectations or
design spec (design for mfg)
Tooling condition
Operator methods and errors
Slide 8
Effective TPM Eliminates 5 Losses
1. Equipment breakdowns
2. Defects, scrap, and rework
3. Safety Issues
4. Mini stoppages
5. Reduced speed


Slide 9
What is TPM??
1. Starts with 5S / Visual Factory
2. Builds a comprehensive Downtime Database by
cause, frequency, and duration
3. Predicts and prevents downtime by PM system
4. Expands role of Operator as first point of early
warning and prevention
5. Develops Professional Maintenance skills


TPM is a Lean tool to optimize the effectiveness of
manufacturing equipment and tooling.

Slide 10
1
2
3
4
5
6
7
Operator Autonomous Maintenance

Countermeasures for Contamination
Initial Standards
General Inspection
Autonomous Inspection
Standardization
Aut. Mgt.
Seven Steps
of TPM

7
6
5
4
3
2
1
Initial Clean-up
Slide 11
TPM is Planned, Predictive, & Preventive
1. Starts with 5S / Visual Factory
2. Builds a comprehensive downtime data
base by cause, frequency, and duration
3. Predicts and prevents downtime by PM
system
4. Expands role of Operator as first point of
early warning and prevention
5. Professional Maintenance


Slide 12
5S Workplace
Sort (organize)
Shine (clean)
Set in order (make orderly and neat)
Standardize (visual place for everything)
Sustain (maintain the system)

A safe, clean, orderly workplace is
fundamental to quality, efficiency, and teams
Slide 13
TPM starts with 5S
You cant see problems clearly when
the workplace is in disarray
Cleaning and organizing the workplace
helps the team to uncover problems
Making problems visible is the first step
of improvement
Clean machines and workplace create
pride & Safety
Slide 14
Downtime Visual Controls
Visual or audio alerts
Abnormality obvious at a glance (e.g. stoppage,
reject, control fault)
Alerting Maint and team leaders
Provide real time scoreboard for employees
Machine down light visible from aisle
Production status board (e.g. actual counts vs. goal)
Scrap counts and downtime minutes
Located in clear view in shop (not in control room)
Simple, self regulating, & employee managed

Slide 15
TPM is Planned, Predictive, & Preventive
1. Starts with 5S / Visual Factory
2. Builds a comprehensive
downtime data base by cause,
frequency, and duration
3. Predicts and prevents downtime by PM
system
4. Expands role of Operator as first point of
early warning and prevention
5. Professional Maintenance

Slide 16
Downtime Database
Categorize at a minimum by Equip, Tooling, C/O, Other
Segmented bar graph for E-T-O lost time
Subcategories for Equip (e.g.)
Hydraulic / pneumatic
Mechanical / lubrication
Electrical / controls
Shot-end components
Subcategories for Tooling (e.g.)
Slides
Cores
Inserts
Ejector pins
Subcategories for Other (e.g.)
Operator error
Materials
Slide 17
Minimum Downtime Tracking
0
20
40
60
80
100
120
Minutes
1Q02 2Q02 Jun Jul Aug Sep Oct Nov Dec
Downtime by Cause 3500 ton Bay
(avg min/shift per Machine)
O
T
E
Equip
Tools
Other
Slide 18
TPM is Planned, Predictive, & Preventive
1. Starts with 5S / Visual Factory
2. Builds a comprehensive downtime data
base by cause, frequency, and duration
3. Predicts and prevents downtime
by PM system
4. Expands role of Operator as first point of
early warning and prevention
5. Professional Maintenance

Slide 19
Predictive Maintenance Tools
Rate/hr vs. target or historical normal output (B/W)
Database
MP2 / maintenance history
statistical probability (frequency & duration)
Physical prediction of impending failure
Sound (bearing)
Temperature (cooling water)
Flash (core pins)
Shot monitoring system
SPC on part geometry
Hydraulic pressure (ejector pins)
Spindle loads (amps)
Fluids / Lubrication analysis (milipore)
Vibration Signature Analysis





Slide 20
Preventive Maintenance System
History of downtime by major machine & tool
Downtime measurement & tracking
Mean Time Between Failures
Average downtime
Pareto of causes at component level (eg L/S or temp sensor)
Cost to maintain
Develop PM cards based on frequency of failure and magnitude of
average lost time (start small & grow)
Limit & prox switches
Shot tip / sleeve
Critical frame and cylinder mounting bolts
Expendable tools
Valves, hoses, packing, seals
PMs have instruction, schedule/frequency & sign-off
PMs / repairs done in window of opportunity when machine is down
Cycle count or date based execution of PMs (eg cutter change)
PM status visual (work completed / not completed)
Slide 21
TPM is Planned, Predictive, & Preventive
1. Starts with 5S / Visual Factory
2. Builds a comprehensive downtime data base by
cause, frequency, and duration
3. Predicts and prevents downtime by PM system
4. Expands role of Operator as first point
of early warning and prevention
One point lessons for operator awareness
Creates OMP (Operator - Maintenance
Partnership)
Operator performs checks, problem
solving, and improvements
5. Professional Maintenance

Slide 22
TPM
Production Operators
Clean & Check
Observe
Categorize
Manufacturing Engineers
Equipment Planning
Equipment Studies
Production Planning
& Control
Schedule P.M.
Quality Engineers
Standards &
Calibrations
Active
Planned
Maintenance
Process
Slide 23
OMP - Operator Maintenance Partnership
Operator training in TPM
Operator basic equip inspection
& tooling checks
Operator basic cleaning
Operator lubrication check
One point lessons (capture
knowledge)
TPM Board & TPM Tags
(proactive operator involvement)




TPM
Slide 24
TPM Tag System
Problem communication tool to and from
maintenance, tool room, and production
Identify abnormal machine conditions
Record problem discovered by operator
Record problem found during scheduled PM
Status tracking system of requested repairs
TPM visual management tool (hang tags)
Repair history for future problem solving
TPM Tag used for recording problem & fix
Blue Tag-Operator or Maint responsible to repair
Red Tag- Safety-related request (priority)


Slide 25
Operator/Supervisor Production Management Maintenance
1. Abnormality Identified
2. Fill out Tag Red= Safety
Blue= Prod/Maint
3. Hang C-tag as close to the defect
as possible
4. Hang A &B Tags on the TPM Tag
status board by Machine location and
area of responsibility to correct.

5.Maintenance evaluates problem. If
fixed immediately go to 6. If parts or
time needed, maint pulls A tag from
board. The A tag is MWO. The B
tag is posted on the Maint WO
status section of the TPM Board with
est. timing.
7. Operator/Supervisor check to see
if work was done.
6.After work is completed,
maintenance completes back side of
A tag and places both the A & B tag
in the work completed box
8. If OK, Operator/ supervisor
removes C tag from machine and
places ABC tags in Completed box. If
not OK, tags stay and maint is
contacted. Contact noted on tag.
9. Production management reviews
the information. Also reviews the
comments and takes actions if
required. Places tag in history file box
located in the office
Tag information is recorded and reviewed for continuous improvement of PM
database by Production and Maintenance; Repeat operator tags may indicate
Maint needs to investigate.
Tag Process
Slide 26
TPM is Proactive, Predictive,
Preventive & Planned
1. Starts with 5S / Visual Factory
2. Builds a comprehensive downtime data
base by cause, frequency, and duration
3. Predicts and prevents downtime by PM
system
4. Expands role of Operator as first point
of early warning and prevention
5. Professional Maintenance

Slide 27
Professional Maintenance
Equip Safety
Skill building
Cross-training
Area Maintenance
WC MRO stores
Maint Mgmt System
Down alarms
Radios
Planned PM
Slide 28
1
2
3
4
5
6
7
Operator Autonomous Maintenance

Countermeasures for Contamination
Prepare Temporary Standards
General Inspection
Autonomous Inspection
Standardization
Aut. Mgt.
7 Steps

7
6
5
4
3
2
1
Initial Clean-up
OIL
T P M
Slide 29
TPM
5S
TPM I
Step 1
Step 2
Step 3

TPM II
Step 4
Step 5
Step 6
Step 7
Initial Focus
prerequisite for TPM I
Slide 30
STEP 3: Prepare Temporary Standards
This step is to enhance the equipment reliability
& maintainability.
Temporary Check Sheet For Clean-Up,
Lubrication, Start-up, and Shut-down:
What items need to be done
Who will perform the check
How often to check
Where the location is to be checked
What to use for the inspection or cleaning
Target time to complete the task
Slide 31
TPM Summary
TPM = Total Productive
Maintenance
Proactive (all employees
involved)
Preventive
Predictive
Planned
TPM is an integral part
of JLF Total Quality
production System


5S
Visual
Factory
T P M
Standardized
Work
Continuous Waste Reduction
Peak Performance
Slide 32
TPM is a Lean tool for
Quality and
Productivity