TPM

1. • Draw up Kaizen sheet and then confirm the result of loss reduction
with comparison between before and after kaizen.
• Revise Kaizen point of drawing, standard and working procedure
• Draw up one point lessons about operator’s skill what was be clear
through kaizen activity.
• After kaizen activity, it needs to install visual control to necessary point.
Productivity Management Office @

2. Why – Why Analysis
• This is an analysis that repeat why about 4M root causes of problem several
times. 4M (Machine, Material, Method, Man)
• First of all, investigate phenomenon and scene to find out cause of problem and
then try to do why-why analysis.
• It is useful not only for production field but also different field.
• The important point for analysis is to be clear what is problem.
• Examine human cause at the end of analysis.
Productivity Management Office @

3. PM Analysis
phenomenon
Contributing condition
Physical viewing
F3 is not zero
4M cause
Vacuum area is
small
Vacuum power is
small
F1 is small less
than standard
Vacuum power is
small less than
falling power
Lift aim can not
pick up tray
Gap of vacuum
position
Tray is heavy
F2 is heavy more
than standard
Lifting power is small

4. Part 5 Consulting Experience sharing
Productivity Management Office @

5. Zero concept and model
Productivity Management Office @
• Zero model machine
• Zero model line
• Zero model area
Zero machine failure
Zero minor stops
Zero quality defect
Zero cleaning etc.

6. Relationship between AM and others
Autonomous maintenance 7steps
• Step 0 Preparation
• Step1 Initial cleaning
• Step2 Countermeasures for source of
contamination and hard to access.
• Step3 Tentative CIL standard
• Step4 General inspection
• Step5 Autonomous inspection
• Step6 Standardization
• Step7 Autonomous management

7. Planed maintenance for Zero failure
Planed maintenance 7 Steps
Step1 Recognition of current maintenance system
Step2 Set up purpose, policy, target.
Step3 Organization formation and clarification
Step4 Clarification of implementation activities
Step5 Study of specific implementation for each activity
Step6 Plan farming for implementation with autonomous maintenance
Stpep7 Result verification and establishment of maintenance system
Productivity Management Office @

8. Example of implementation activities
1. Support activity of Autonomous maintenance
2. Zero failure activity
3. Lubrication management activity
4. Spare parts management activity
5. Maintenance skill up and new technology activity
6. Maintenance cost down activity
7. Maintenance management system activity
8. Maintenance project management activity
Visualize maintenance procedure
Productivity Management Office @

9. Kaizen scenario of sales growth
• Cooperation is significant between sales and manufacturing
• Can make but can not sale, can sale but can not make
• Which production system is better A or B?
• Which product is better for kaizen A or B?
Sales
Sales P2
P1
a
b
s
0 1 2 3 4
Productivity Management Office @
Contrary
For cost
Contrary
For profit
Opportunity loss
Volume
Opportunity loss

10. Kaizen scenario of cost down
• It should be improved difference of cost and aimed for Real standard cost.
• It should be considered ideal standard cost (long term) and real standard cost
(short term).
Actual cost
Productivity Management Office @
Standard cost
Present standard cost
Real standard cost
Ideal standard cost Level3 : Target cost in future
Level2n : Target cost after kaizen
Target1 : Target cost at present
= Actual cost – standard cost
Actual loss (difference of cost)

11. Loss analysis ( Loss tree )
• It makes clear loss structure and plan strategy.
Productivity Management Office @
Past loss
Forecast loss
Past
Opportunity
loss
Opportunity
loss
Production cost
loss
Production losses
Production
cost loss
Indirect
Production loss
Claim loss
Stock loss
Sales
Management loss
Past loss

12. Management of Kaizen theme
• Team leader manages individual kaizen theme and Focused improvement
subcommittee manage whole themes by matrix as below.
Productivity Management Office @
Large theme Middle theme Small theme Initial Target Actual Parson
Date of
begin
Date of
end
Achievement
Theme 1
Theme1-1
Theme1-1-1
Theme1-1-2
Theme1-2
Theme1-2-1
Theme1-2-2
Theme1-2-3
Theme1-2-4
Theme1-3
Theme1-3-1
Theme1-3-2

13. Part 6 overall Program Summary
Productivity Management Office @

14. Key of success
1. Clear TPM policy of top management
2. Alignment between Business plan and TPM plan
3. Management of plan, target and results
4. Priority themes and model activities
5. Incentive for full participation
6. Leadership of each level
7. Budget for TPM activity.
Productivity Management Office @

15. Tangible result of TPM ( Example)
• P Value-added Productivity x1.5~
Number of Unexpected break down 1/100~
Overall equipment efficiency x1.5~
• Q Quality defect in process 1/10~
• Customer claim ¼~
• C Valuable cost down 30%~
• D Inventory ½ ~
• S Zero accident zero
• Environmental pollution zero
• M Turnover ½~

16. TPM Award
1) Award for TPM Excellence, Category B
The applicant must score a minimum of 70 points on 100-point Checklist C.
2) Award for TPM excellence category A
The applicant must score minimum 70 points on 100 point checklist c
3) Award for excellence in consistent TPM commitment
The applicant must score minimum 80 points on 100 point checklist c
4) Special award for TPM achievement
The applicant must score minimum 70 points on 100 point checklist B
5) Advanced special awards for TPM achievement
The applicant must score minimum 80 points on 100 point checklist A
6) Award for world class TPM achievement
The applicant must score minimum 80 points on 100 point checklist S
1st Stage Assessment : May-July 201x 2nd Stage Assessment : October-December 201x
+

17. • Checklist C example
TPM policies and objectives
1.
1. TPM policies are planned in relation between company policies and plant/factory policy
2. The relation between TPM target values and management target results are clear
3. The master plan is in an appropriate order as an action plan to achieve TPM
4. TPM policies and objectives are checked using method such as benchmarking that all sections of PQCDSME are
displayed corresponding to 8 pillars
5. TPM policies and objectives are have been set forth and observed by all the departments