TPM METHOD
TPM
GLOBAL INDICATOR: THE TRS
TRS =
Quality production time
Opening time
TRS =
Number of good parts produced x Cycle time
Opening time
Cycle time = Initial reference + improvements
Initial ref. = Minimum technical time
TPM
RELIABILITY INDICATOR
Average of good working time
MTBF =
Actual production time
Number of real stoppages
TPM
RELIABILITY INDICATOR = MTBF (mean time between failure)
It is the average duration in minutes during which the machine or the installation functioned without any stoppages.
The stoppages are:
- machine breakdowns
- breakdowns related to tools
- breakdowns related to the product
- stoppages for change-overs (used or broken)
- stoppages for frequent adjustments
- stoppages for inspection (SPC sampling)
- stoppages for maintenance Stoppages for tool change-overs are not taken into account
TPM
BREAKDOWNS AND MICRO-STOPPAGES:
BREAKDOWNS
Stoppages >= 5mins
Not often
Systematically noted
Stoppage affects the entire working group
Intervention of an expert
Research necessary before start-up
Identifiable causes
MICRO-STOPPAGES
Stoppages < 5mins
Often
Not noted
Little or no perception by the group
Easy start-up without elimination of the cause (suppression of the effect)
Non identified causes
Little motivation to eliminate them because little perceived impact on production
Strongly involve the operators and automatic installation people for tasks without Added Value
TPM
DATA COLLECTIONS
BREAKDOWN RECORDS OF THE LAST 6 MONTHS
PRODUCTION NOTEBOOKS
OPERATOR EXPERIENCE
THE DATE OF THE LAST TECHNICAL MODIFICATION DONE ON ONE PART OF THE MACHINE
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Pareto of unsolved breakdowns of the last 12 months
Eliminate from this database the solved breakdowns
Priority is to solve breakdowns that represent the highest stoppages
Repetitive breakdowns must be highlighted
breakdown1
breakdown2
breakdown3
breakdown4
breakdown5
breakdown6
TPM : Breakdowns
Pareto analysis of breakdowns
TPM: BREAKDOWNS
TREATMENT METHODOLOGY
Register the anomalies (including the breakdowns)
Carry out the repairs
Define the actions to avoid recurrence
Confirm the cause
Steering: Supervisor
Execution: Maintenance Prof. / Workshop Technician
Method: Management of operations and spare parts
Steering: Supervisor
Execution: Maintenance Prof. + TA + Supervisor
Method: 1h30 meeting once a week, 5 Why or eventual creation of a PSG
Steering: Supervisor
Execution : Operators
Method: Record on a notebook near the machine or installation as they occur
PROCESS
People Concerned
Methods
Know the history of breakdowns and current work
Tps interv. Resp.
0 to 5 mins: GAP
5 to 15 mins: Tech
>15 mins: Expert
> 30 mins: Maintenance
2
1
3
4
TPM: BREAKDOWNS
TREATMENT METHODOLOGY
Create or modify if necessary the routine sheet of preventive maintenance
Apply the new standard
Steering: Supervisor
Execution: Maintenance Prof. + Supervisor
Method: Update and validation of routine sheet.
Steering: Supervisor
Execution : Operators + Maintenance Prof.
Method: Following the level of maintenance, define the training needs and train the contributors
Steering: Animation to reach objectives
Execution: Application of formalised instructions
5
6
The history of breakdowns is the back-up document of the process, it is found on the machine and is available for everybody.
It is completed by the person carrying out the given task
TPM: BREAKDOWNS
WEEKLY MEETING
SUBJECT: breakdowns encountered during the week
PARTICIPANTS: supervisor and maintenance technician
GOAL: ensure that the definitive measures have been implemented to avoid any recurrence of breakdowns
PLAN:
weekly breakdown inventory for the past week
examine causes
actions to be implemented
TPM
MICRO-STOPPAGES : CHARACTERISATION
Shut-down < 5mn
Often
No records
Little or no perception by the group
Easy start-up without elimination of the cause (suppression of the effect)
Unidentified cause
Little motivation to eliminate them because little perceived impact on production
Strongly involves the operators and automatic installation people for tasks without Added Value
TPM: MICROSTOPPAGES
TREATMENT METHODOLOGY
From the noted effect, define the diagnosis method of causes
Register the micro-stoppages
Select the micro- stoppage to be treated
Quantify the causes (counting)
Identify the possible causes of the micro- stoppage
PROCESS
People Concerned
Methods
Steering: Supervisor
Execution: Operators, Supervisor, Maintenance and Manufacturing Engineering Technicians
Method: meetings on the shopfloor with problem solving tools ( Pareto - Brain Storming - 5M cause-effect diagram - 5 Why's)
Steering: Supervisor
Execution: Technicians and Operators
Method: Use of exhaustive film of all the machine anomalies (with follow-up of human intervention). Pareto
Steering: Supervisor
Execution: Operators
Method: Noted on numbered workstation form (counting)
Steering : Supervisor
Execution: Maintenance Expert
Method: Formalise and train the operator in diagnosis
2
1
3
5
4
Select the machines
TPM: MICROSTOPPAGES
TREATMENT METHODOLOGY
Create or modify if necessary the routine sheet of preventive maintenance
Select the causes to be treated in priority
Set-up the solutions
Look for solutions
Continue with the "counting" of causes of the micro-stoppage
Steering: Supervisor
Execution: Manufacturing Engineering Technician - Maintenance Prof. - Operators
Method: Depending on the level of machine modification and/or level of maintenance
Define the training needs and train the contributors
Steering: Supervisor
Execution: PSG members
Method: Pareto - Balancing - Brain storming
Steering: Supervisor
Execution: Operators
Method: Noted on workstation form (counting)
Apply the new standard
9
7
6
10
8
11
TPM
ROLE OF THE OPERATOR
PREVENTIVE MAINTENANCE
Carry out production operations correctly and set up the machine
Do inspection of the machine everyday
Maintain the performance of the machine
Cleaning, Greasing,Tightening
Apply the self maintenance routine sheets
Communicate with maintenance department
Carry out the "counting" of micro-stoppage registration sheets
Carry out the recording of micro-stoppages causes
Participate with engineering and trial of new equipment
TPM
ROLE OF THE OPERATOR
CURATIVE MAINTENANCE
Prepare the machine conditions for repair
Give their feelings about the machine and their opinions about the working conditions
Assist technicians during repair and heavy maintenance
Participate in PSG to identify solutions for micro-stoppage and breakdown
TPM: MICRO-STOPPAGES
OPERATOR TRAINING
Steps during which the operator becomes trained
Elaboration of cause-effect diagram
Diagnosis of the causes of micro-stoppages
Research for solutions
Creation or modification of the preventive maintenance routine sheet
Acquired knowledge
Construction of a cause-effect diagram, methodology and research of causes, knowledge of factors responsible for the correct functioning of the machine
Diagnosis methodology of a malfunction
Technical knowledge
Knowledge of machine maintenance needs
TPM
PREVENTIVE MAINTENANCE
Train and assist the operators
Improve the reliability of the machine and standardise identical equipment
capability, features
cycle time
Improve maintainability
Do technical inspection that need expertise
Continuous improvement of maintenance organization
Participate in the engineering of new equipment
ROLE OF THE MAINTENANCE DEPARTMENT
TPM
Examples of visual means
Position markings (machines, tooling, tools, products, etc.)
Colour coding by function, product or workshop
Light paint on dirty objects
Cupboards without doors
Etc...
VISUAL ORGANISATION
Experience analysis
TPM: preventive maintenance
Janvier
Février
Mars
Avril
Mai
Juin
Juillet
Septembre
Octobre
Novembre
Décembre
Vidange moteur
Vérification serrage vis support bâti
Graissage carter
Contrôle tension et usure courroie
Contrôle dimensionnel axe
Machine
Atelier
Configuration initiale
Date:
Ensemble
Note:
Nouvelle configuration
Board for scheduling the preventive maintenance
Preventive maintenance procedure
Report of the inspection anomalies
Historical account
1
2
3
3
4
5
Weekly meetings
Property of Valeo - Duplication prohibited
Janvier
Février
Mars
Avril
Mai
Juin
Juillet
Septembre
Octobre
Novembre
Décembre
Vidange moteur
Vérification serrage vis support bâti
Graissage carter
Contrôle tension et usure courroie
Contrôle dimensionnel axe
Board or datasheet for scheduling the preventive maintenance
To be done
JL
Observed defect
finished
JL
Nothing wrong
TPM: preventive maintenance
Working conditions
Property of Valeo - Duplication prohibited
EXAMPLES
Obvious TPM
Visual mark for Min and Max levels
Mark to locate the stop position of a mobile part of a machine
Red mark for pressure manometer
Important screws with nut tightening are repaired with visual mark (see 2 on page 49)
Grease locations are highlighted with arrows, numbered and coloured
Part list is labelled on containers (oil tank, pump for greasing operations...)
EXAMPLES
Obvious TPM
1
2
3
FIELD APPLICATION
TPM
PILOT WORKSHOP
CRITERIA
Line or bottle-neck machines (in order to gain capacity and availability)
Presenting a low "MTBF"
Strongly penalising the flow
Semi-automatic installations consisting of manual workstations (the activity of the operator depends upon the good functioning of the installation)
schedules
Preliminary "5S" operations
implementation of cleaning procedure
implementation of inspection procedure
visual organisation
TPM methodology
TRS measure
MTBF measure
Treatment of breakdowns
Treatment of micro-stoppages
Complement the preventive maintenance procedure
TPM
TPM: MICROSTOPPAGES
TREATMENT METHODOLOGY
From the noted effect, define the diagnosis method of causes
Record the micro-stoppages
Select the micro- stoppage to be treated
Quantify the causes (counting)
Identify the possible causes of the micro- stoppage
PROCESS
People Concerned
Methods
Steering: Supervisor
Execution: Operators, Supervisor, Maintenance and Manufacturing Engineering Technicians
Methods: meetings on the shopfloor with problem solving tools ( Pareto - Brain Storming - 5M cause-effect diagram - 5 Why's)
Steering: Supervisor
Execution: Technicians and Operators
Methods: Use of exhaustive film of all the machine anomalies (with follow-up of human intervention). Pareto
Steering: Supervisor
Execution: Operators
Methods: Noted on numbered workstation form (counting)
Steering : Supervisor
Execution: Maintenance Expert
Methods: Formalise and train the operator in diagnosis
2
1
3
5
4
Select the machines
TPM: MICROSTOPPAGES
TREATMENT METHODOLOGY
Create or modify if necessary the preventive maintenance routine sheet
Select the causes to treat in priority
Set-up the solutions
Look for solutions
Continue the "counting" of the causes of the micro-stoppage
Steering: Maintenance, Manufacturing Engineering
Execution: Manufacturing Engineering Technician - Maintenance Prof. - Operators
Method: Depending on level of machine modification and/or level of maintenance
Define the training needs and train the contributors
Steering: PSG Leader
Execution: PSG team members
Method: Pareto - Balancing - Brain storming
Steering: Supervisor
Execution: Operators
Method: Registered on workstation sheet (counting)
Apply the new standard
9
7
6
10
8
11
Look for solutions
TPM WORKSHOPS RESULTS
FEEDBACK TO DESIGN
specification book
set up / start of the machine
Up'dating of preventive routine datasheet
Collection of experience
Building of preventive maintenance booklet
FMECA
5"S"
TPM
Supplier
advices
breakdown
Micro-stoppages
Quality
Safety
PREVENTIVE MAINTENANCE ELABORATION
FMECA
TPM: FMECA
Failure Modes and Effects Criticality Analysis
Tool to improve understanding of the working conditions and the stop risks of a machine
Identify the weak parts of a machine
Study effects of failure (Reliability Maintainability Risk Safety)
Study and plan solutions for corrective and preventive actions to improve reliability
Rules to operate the machine to its optimum
TPM: FMECA
Thinking approach
CAUSE : Why did it occur ?
EFFECT : What has happened according to the machine operator ? The machine itself ?
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TPM: FMECA
Quotation
Gravity
value
Minor
Midle
Critical
disastrous
Repair time
< 5 min
Repair time
between 5 &15mn
Repair time
between 15 &60mn
Repair time
>60mn or quality / saafety risk
Frequency
value
Annual
quarterly
weekly
daily
Less 1 fault/year
rMax
1 fault/quater
Max
1 fault/week
1 fault/day
Detection
probability
Minor
Middle
Critical
disastrous
Detection
probability
Previous signs before failure leading to preventive maintenance
Previous indications but none noticeable for the operator
No Previous sign before failure
Previous signs before failure but difficult to see by the operator
Correctives actions
TPM: FMECA
Risk priority index IPR = G x F x D
1
16
64
IPR
causes number
correctives actions
necessary
THE MAINTENANCE PLAN
TPM
The current maintenance plans are established from recommendations from the machine manufacturer and do not take into account any specific use and realities observed in the field
THE MAINTENANCE PLAN
TPM
The TPM approach allows the :
Organisation of observations
Construction of maintenance plans from the observation of reality
Training of operators from these new plans
TPM
MISSION AND RESPONSIBILITIES OF A TPM LEADER
Definitions
Mission of area
Concise summary of what the studied organisation section should carry out
Responsibilities (of area and its members)
Areas of activity or of competence in which the area has been delegated, was designated for or is considered as particularly competent
Activities of section members (the "actors")
Concrete tasks are carried out by the personnel in order to assume their responsabilities and accomplish their mission
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TPM
Process
Determination of the mission and of responsibilities
Determination of customers and of their requirements
Determination of suppliers and of their requests
Validation of requests with the customers
Validation of requests with the suppliers
Evaluation and redistribution of means to satisfy the new requests - action plans
Implementation and follow-up of indicators
MISSION AND RESPONSIBILITIES OF A TPM LEADER
