TPM the effective maintenance (2)

1. TPM the Effective Maintenance (23/30Apr2016) For: Kotak Malaysia (KOM) Sdn Bhd 11-12 Jln Usaha 4, Kawasan Perindustrian, 75450, Ayer Keroh, Melaka Darul Azim. Presented by: Timothy Wooi ITS Management Sdn Bhd

2. 2016/4/29 2 TPM the Effective Maintenance

3. TPM Implementation after (AM) & Maintenance Workshop Activities Review & extract Equipment PM to a ‘Do Dot’ Visual Master Plan & Visual TPM Board. Attacking 6 big losses of Equipment (PdM) with Engineering Kaizen to maximize Equipment Utilization Quality, Engineering & Maintenance Kaizen Improvement Action Projects & Action Plans TPM the Effective Maintenance

4. Maintenance and Reliability is a core business strategy. The key to a successful TPM implementation is Top Management support. To implement TPM successfully, a 12 steps approach is used. This will lead you to the road to:“ zero breakdowns” and “zero defects’’ Course Overview TPM the Effective Maintenance

5. To enable Participants understand TPM, after that to Plan, Develop, Implement and oversee the Maintenance program towards a Zero downtime by; Course Objective TPM the Effective Maintenance  executing Equipment Maintenance timely per schedule and reduce Company’s resources efficiently using ‘low cost or no cost’ techniques as practiced in a Lean and World class Environment.

6. 2016/4/29 6

7. With TPM the focus of maintenance shifts from that of repairing, or reacting to failures to that of maintaining assets and preventing failures and quality defects in the first place. TPM the Effective Maintenance The root word of maintenance is Maintain, more often than not maintenance is looked at as the people that repair our equipment when it breaks.

8. Maintenance Operations TPM Safety and Environmental Training and Education Autonomous Maintenance Autonomous Maintenance Workshops Planned Maintenance Moving from reactive to proactive maintenance Attack Six Big Losses •Equipment failures •Setup and Adjustment •Idling and minor stoppages •Reduced speed •Defects and rework (quality) •Start up losses (reduced yield) New assets meet production needs and minimize Life Cycle Costs (LCC) Early Equipment Design and Start up Management TPM the Effective Maintenance

9. to Extend life span of Equipment and Tools preventing damages caused by neglect and to cut cost of new Equipment reinvestment. TPM the Effective Maintenance  to improve Productivity and Quality leading to Increased Profit by eliminating unplanned breakdowns and costly downtime. Failure Purchased Condition Improved Condition Life Cycle Time Failure Improved Asset Condition Forced Deterioration Equipment Failure TPM Team Based Action

10. 2016/4/29 10 TPM teaches to plan ahead by preventing equipment failures and quality defects before they occur. TPM the Effective Maintenance

11. 3P Maintenance TPM after AM (Plan, Preventive & Predictive) Step 9: Re access planned or preventive maintenance program. Create a schedule for preventive maintenance on each piece of equipment. Step 10: Conduct training to improve operation and maintenance skills. Maintenance department will take on the role of teachers and guides to provide training, advice, and equipment information to the teams. Step 11: Develop an early equipment management program. Apply preventive maintenance principles during the design process of equipment. Step 12: Continuous Improvement - As in any Lean initiative the organization needs to develop a continuous improvement mindset.

12. The main TPM kick-off should take the form of a formal presentation with all the employees attending. TPM Implementation after AM 5.5. TPM kick-off This opportunity can be used to gain the full support of the employees Invite external customers, affiliated and subcontracting companies TPM the Effective Maintenance

13. * Preparation Kick-off Implementation Announcement to introduce TPM Introductory education campaign for the workforce TPM Promotion (special committees) Establish basic TPM policies and goals Preparation and Formulation of a master plan Develop an equipment management program Develop a planned maintenance program Develop an autonomous maintenance program Increase skills of production and maintenance personnel Perfect TPM implementation and raise TPM levelsStabilization Develop early equipment management program Invite customers, affiliated companies and subcontractors

14. A handing-over of maintenance tasks from specialized maintenance personnel to production operators Promote the 7 steps Tasks to hand over cleaning lubricating inspecting set-up and adjustment 14 = Establish a Baseline Energy Awareness Cleaning is Inspecting Eliminating Contamination Visual Management Equipment Maintenance Equipment Lubrication Consumables Total Productive Maintenance

15. A master plan lays out your goals, what you will do to achieve them and when you will achieve them. Detailed plans for each pillar have to be prepared TPM the Effective Maintenance Determining PM frequencies and how to schedule PM :  Time-based or usage-based scheduling  How to measure PM effectiveness and results  How to measure and analyze downtime and downtime trends

16.  How to Develop and Install a Good PM System -Do Dot Visual Master Plan & TPM Board  Maximizing Equipment Utilization –Attacking the 6 Big loses  Engineering TPM Kaizen -Improvement Projects to address risk of breakdown - 10 Steps to Improvement Action Plan timothywooi2@gmail.com TPM the Effective Maintenance Workshop Activities

17. Form project teams Select a base line (model equipment) *identify equipment problems *analyze equipment problems *develop solutions and proposals for improvement The tools of Total Quality Management and Continuous Improvement are applied to the management and improvement of equipment TPM the Effective Maintenance

18. 2016/4/2918 The goal is to: Provide guidance in identifying and developing lubrication requirements, routes, and visual cues for the proper lubrication of equipment. Equipment Lubrication

19. 19 70% of all mechanical equipment failures are a result of improper lubrication. Too much lubricant is as bad as too little S S S S S Equipment Lubrication S S S S S TPM the Effective Maintenance

20. Set up plans and schedules to carry out work on equipment before it breaks down, in order to extend the life of the equipment Include Preventive and Predictive Maintenance Include management of spare parts and tools

21. 2016/4/2921 The goal is to: Have a routine schedule of activities for maintaining the asset in a highly reliable condition. Pull together all the processes and tasks developed in previous modules relating to maintenance of the equipment. Ensure PMs are up to date. If PMs are not available, they should be created for this equipment. Equipment Maintenance Work with Reliability Team to install condition-based monitoring devices.

22. 22 Tool Maintenance

23. Call for vibration check when Hour Meter reads 250 Pull Bearing Packs and Inspect when Hour meter reads 4000 Call for oil analysis when Hour Meter reads 2000 216 93 1394 Spindle #1 Servos Power On Hrs Hrs Hrs Example: Condition-based monitoring devices. TPM the Effective Maintenance

24. 2016/4/2924 The goal is to: Develop a list of consumable items needed for the routine maintenance of your equipment. Have a Parts Change History record. Establish minimum and maximum quantities, identify standard storage locations at point of use, and apply visual management. Consumables

25. Components of a Well-organized P/PdM Program  Equipment inventory/numbering system  Critical Spare parts inventory/forecast  Sequence of tasks (PM and PdM routes) Machine maintenance critical spares Critical spares for water jet cutter machine Item P/N 1Hi pressure seal kit 001198-1 2Low pressure seal kit 010641-1 3 Mixing tube 010460-40- 30 4Orifice assembly 014201-10 5Repair kit on/off valve 010200-1 6Swivel assy single axis 010140-1 7Cutting head assy 8Repair kit 3/8 swivel 007117-1 9Pressure valve control Example Critical Spare List

26. Parts changed history for each machine/equipment ( source of data: finance department based on PO for period from Jan 02 to 29 Jun 04) Equipment Name: Asset No.: Location: Data of purchase: Date Part change Part no. Description RM/unit qty changed Total RM Consumables How to keep an effective and useful equipment history

27. On existing machines: Analyze historical records for trends of types of failures frequency of component failures root causes of failures Determine how to eliminate the problem and reduce maintenance through an equipment design change or by changing the process TPM the Effective Maintenance

28.  Increase Overall Equipment Effectiveness (OEE)  Improve existing planned maintenance systems  The operator is the best condition monitor  Provide training to upgrade operations and maintenance skills  Involve everyone and utilize cross-functional teamwork TPM the Effective Maintenance

29. Maximizing Equipment Utilization –Attacking the 6 Big loses timothywooi2@gmail.com TPM the Effective Maintenance Set-Up and Adjustment Idling and Minor Stoppage Reduced Speed Quality: Defects in Process & Rework Reduced Yield Equipment Failures Easy to measure Low Impact on Profit High impact on profits Labor Materials/spares Outside services Maintenance overhead

30. 4/29/2016 30 Failures DefectsSetup and Minor Stoppage Reduced Equipment Reduced Yield in ProcessAdjustment Idling and Speed Availability Efficiency Quality + + + Overall Equipment Effectiveness X X OEE is an internationally accepted measure of equipment effectiveness during planned production. It measures how effective equipment is at adding value to the manufacturing process.

31. 2016/4/29 31 Attacking the Six Big Losses for OEE (Overall Equipment Effectiveness) To achieve World class OEE  Availability > 90%  Efficiency > 95%  Quality > 99%  90 x 95 x 99 = 85% OEE (Most companies find their OEE at 40 – 50% before TPM) World class OEE is 85% TPM the Effective Maintenance

32. Equipment Usage Effective Production Value Added TPM the Effective Maintenance (Most companies find their Value added Equipment usage to be only at 40 – 50% before TPM)

33. 2016/4/29 33 Human Neglect Forced Deterioration Minor Defects Frustration Losses #1 Cause of equipment failures TPM the Effective Maintenance

34. If you asked a Japanese person from a World Class manufacturing company what maintenance means they would probably say: Maintenance means maintaining and improving the integrity of our production and quality systems through the machines, processes and people who add value to our products and services. TPM the Effective Maintenance

35. Failure Purchased Condition Improved Condition Life Cycle Time Failure Improved Asset Condition Forced Deterioration Equipment Failure TPM Team Based Action PM PM PM PM PM PM PM PM TPM the Effective Maintenance

36. Workshop Activities This Workshop is designed to equip Maintenance Personal with knowledge of Maintenance TPM after A M to:  Focus on the Equipment Maintenance using ‘Do Dot’ Visual Master Plan Check sheet. Ensure timely execution of (PM) with Production and Management support Execute (PdM) with Engineering support to ensure Equipment are are always in a ‘ready to use’ condition ‘every time’ towards a ‘Zero Downtime’ as the Goal. Overview

37. 4/29/2016 371) Evaluate the current condition of the equipment 2) Improve the conditions to what they should be 3) Evaluate or prepare Preventive Maintenance inspection standards 4) Implement Proactive maintenance to extend service life 5) Improve Inspection and Maintenance efficiency 6) Implement Quality Maintenance 7) Implement CBM

38. 2016/4/29 38

39. How to Implement Maintenance TPM -3P (Plan, Preventive & Predictive) Maintenance Workshop Review Maintenance TPM -Analyze existing Equipment condition and set SMART goals.(Choose 1 Equipment first).Example:-……………………………… Revisit Preventive Maintenance Checklist & effectiveness of Execution. TPM kick-off.. & TPM Board 12 Steps to TPM Installation (after step 8 )

40. How to Develop and Install a Good PM System timothywooi2@gmail.com Maintenance Workshop Do Dot Visual Master Plan & TPM Board

41. Do Dot Visual Master Plan sample Maintenance Workshop Critical Consumerable Spares Re-stocking Plan Date:31-May-06 ( Source of data: Spare parts changed from Jan 04 to May 06 based on Avialability vs Lead time) Equipment Name: Gerber Kit cut Asset No: No Part Part Source & Unit Price Lead Time Stock Level Name Number Contact NUmber (US$) (Days) Curren t Min Max 1Theta axis pulley CR2-033 1 2 2Theta motor A-CR2-194 1 2 3Linear bearing CR2-053 1 2 4Keypad CR2-044 1 2 5Galil mation control card DMC-1040 1 2 6Amplifier icon card A-CB2-110 1 2 7Y axis inter connect card CR2-041 1 2 8X Y axis motor A-CR2-193 1 2

42. Team D Suggested Layout of I nform ation Board Suggested Layout of Information Board • Board measures 36X48 mounted -- 40 to 48 inches from the floor • Attach Consumables list to TPM cabinet door • Lockout instructions & map to be located on main electrical cabinet (not on TPM Board) Lube Critical Cleaning Route Map Problem and Component Codes MSS Equipment Problem Log Sheet (S.R. Record) OEE Weekly Summary Sheet (if Available) P.M. Schedule List of persons responsible for updating each item on this board TPM Information Board Machine OperatorMachine Name Operators’ Name(s) Instructions for Lube & Critical Cleaning Any Single Point Lesson place behind these instructions TPM Management Walk-through Checklist Small Group Activity Improvement Items (form) Start-up/Shutdown Process Map on Back Team D Note: Board construction wood with cork facing or magnetic Operator Sign-off Sheet (daily)

43.  Quality & Kaizen Overview Quality Improvement Action Plan  Engineering TPM Kaizen -Improvement Projects to address risk of breakdown  Maximizing Equipment Utilization After Maintenance Workshop TPM the Effective Maintenance

44. 2016/4/29 44 Gradual, unending improvement, doing “little things” better every day, setting and achieving ever higher standards Engineering TPM (Kaizen) TPM the Effective Maintenance -Improvement Projects to address risk of breakdown

45. The Key to One Piece Flow, Just In Time and Lean Manufacturing IS

46. Raise inspection and restoration skill levels Review and improve Cleaning is Inspecting and Lubrication Standards Enhance visual controls Ensure operators and maintenance are creating Single Point Lessons Strengthen Routine Maintenance TPM the Effective Maintenance

47. Raise the level of inspection for Operators through Small Group Activities (SGA) and start focusing on attacking the Six Big Losses of Production as a baseline. Higher level of inspection TPM the Effective Maintenance Maintenance to Train Operators on Basic: *Pneumatics *Hydraulics *Electrical Systems *Drive systems *Machine Specific Training

48. 2016/4/29 48 Pneumatic systems Hydraulic Systems Electrical Systems Drive Systems Machine Specific Training Skill Specific Training Maintenance Training For Maintenance group should then focus on Advanced:

49. *Why are we concerned about equipment lubrication? *Many moving parts are not lubricated *Many components are over lubricated *Lubricants already in components are contaminated Failures Components Resources Quality 28

50. 50 Lubrication (Yellow) Air/Vacuum (Blue) Hydraulic (White) Water (Green) Electrical (Red) Lockout/Tag/Tryout (Orange and Black) Inspection Checkpoints (White and Black)3 INSPECTION POINT AIR PRESSURE 80-100 psi #1 Main Air Supply LOCKOUT Work place Organization Standards ( Visual Management of Equipment) - Color Coding

51. 2016/4/29 51 Visual Management Examples

52. 2016/4/29 52 * Single Point Lessons let you quickly (ten minutes or less) communicate key points on any subject either verbally or visually. You can augment your lesson with visual support if appropriate. Suggested topics for lessons include, though not limited to: A specific maintenance procedure An inspection task for Quality Control A detail of a safety check An office procedure, such as record keeping for AM A well prepared Single Point Lesson stands alone, and can be delivered by anyone who feels comfortable doing so, whether or not they are a subject matter expert.

53.  Elements of PdM (mechanical and electrical)  Equipment condition monitoring  Predicting potential equipment breakdowns or to avoid expensive repairs 3P Maintenance TPM (Plan, Preventive & Predictive Maintenance) TPM the Effective Maintenance Predictive Maintenance Techniques, Applications, and Instrumentation covers;

54.  Starting with a PdM base line (History of Failure)  Retighten PM Schedule to include PdM  Combining PdM with PM for greatest overall effect and least cost Organizational requirements TPM the Effective Maintenance Predictive Maintenance (PdM) Implementation Getting Organized for PdM &Planning for PdM, the preparatory steps;

55. Typical membership of a team *five to seven operators *a maintenance person *a technical expert Tools *Pareto *Cause & effect *Root cause *Methods Analysis TPM the Effective Maintenance

56.  Vibration analysis/monitoring  Shock pulse method  Spectrographic oil analysis  Ferrographic particle analysis  Thermography/temperature measurement  Non-destructive testing (NDT)  Ultrasonic testing and more Specific PdM Techniques and Applications TPM the Effective Maintenance

57. A manager that does not spend 20% of their time involved in TPM is only offering lip service Tokutaro Suzuki Vice Chairman, Japanese Institute of Plant Maintenance TPM the Effective Maintenance

58. shop floor attitude TPM the Effective Maintenance

59. I run it, you fix it I fix it, you run it Total Productive Maintenance is Not, TPM the Effective Maintenance

60. Autonomous Maintenance is Not TPM the Effective Maintenance

61. For Choosing ITS Management Sdn Bhd As Your Training Provider If you have questions or require further assistance later, please email to Itslc98.help@gmail.com Email Subject: “Attn: Timothy Wooi” Other inquiries, please email to itslc98@gmail.com

TPM the effective maintenance (2)

TPM the effective maintenance (2)

Recommandé

Contenu connexe

Tendances

Tendances(20)

En vedette

En vedette(20)

Similaire à TPM the effective maintenance (2)

Similaire à TPM the effective maintenance (2)(20)

Plus de Timothy Wooi

Plus de Timothy Wooi(20)

Dernier

Dernier(20)

TPM the effective maintenance (2)