tpm the effective maintenance with autonomous maintenance

TPM the Effective Maintenance

(23/30Apr2016)For: Kotak Malaysia (KOM) Sdn Bhd11-12 Jln Usaha 4, Kawasan Perindustrian, 75450,Ayer Keroh, Melaka Darul Azim. Presented by: Timothy WooiITS Management Sdn Bhd

Course Overview This is a 2 days course on Total Productive

Maintenance (TPM) that will guide you through to implement Autonomous Maintenance (AM) on your current Equipment and to plan the execution of your Preventive (PM) & Predictive Maintenance (PdM).

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TPM defines your Maintenance schedule and Goals. TPM helps you plan and develop the optimal program for your facility, resulting in increased efficiencies and cost savings.


Course ContentDay 1

TPM General Overview with Autonomous Maintenance (AM) as the back bone of TPM 6 Steps to Autonomous MaintenanceAudit , Review & Externalize Inspection Activities

from Equipment Manual to (AM)Executing Equipment Audit to start (AM) & (PM) -TPM Board & AM Checklist with Visual Management Implementation.


Day 2How to Implement Maintenance TPM after (AM)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

Course Content


TPM is a company-wide team-based effort to build quality into equipment and to improve overall equipment effectiveness of Preventive & Predictive Maintenance.

TPM Overview

It uses Total Quality Control and Total Employee Involvement approach, in maintaining the Equipment towards a “ready to use condition” using energy efficiently.


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TPM combine Production practices in Autonomous Maintenance (AM) and the Maintenance practices, both working together as a Team to maintain the smooth running of a Company’s Equipment towards a Zero Breakdown. TPM Maintenance covers;

Autonomous Maintenance (AM)

Preventive Maintenance (PM)

Predictive Maintenance (PdM).

TPM the Effective Maintenance TPM Overview

I run it,you fix it

I fix it,you run it

TPM is Not

Maintenance Workshop Activities

This Workshop is designed to equip Maintenance Personal with knowledge of Maintenance TPM after Autonomous Maintenance to:

Focus on the Equipment Maintenance using ‘Do Dot’ Visual Master Plan Check sheet.

Ensure timely execution of (PM) with Production and Management support and…

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

To enable Participants understand TPM, after that to Plan, Develop, Implement and oversee the Maintenance program towards a Zero downtime by;

Workshop Objective


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 (WCM).

to Extend life span of Equipment and Tools preventing damages caused by neglect and to cut cost of new Equipment reinvestment.

to improve Productivity and Quality leading to Increased Profit by eliminating unplanned breakdowns and costly downtime.

Workshop Objective


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Where are we today?

Is most of your time spent ‘fire fighting’?Are equipment failures and quality issues a problem?Is very little time spent on preventing the failures and quality defects from occurring?Do you have waste of ‘repair’ in your facilities?

Total- in TPM means ‘total involvement’ from top management to shop floor personnel. TPM is not optional, everyone has to participate for it to work. The biggest reason why TPM failed is that “people do not have enough time doing it”. Time is either dedicated to TPM, or spent fire fighting breakdowns and quality defects. Having time for breakdowns, we certainly have enough time for TPM.Productive- Creates cost saving and also creates cost avoidance.


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Where do we want to be?

TPM teaches to plan ahead by preventing equipment failures and quality defects before they occur.

Step 7: Full Autonomous Maintenance implementation using AM Check List & TPM board Visual Management

TPM can be only be successful, only with universal co-operation of Production and Maintenance. Production carries out Autonomous Maintenance whilst Maintenance group carries out the 3P Maintenance.


Autonomous Maintenance is carried out by Production Department in Seven steps. Step 1: Establishing a baseline Step 2: Cleaning is InspectingStep 3: Visual ManagementStep 4: Cleaning and lubrication Step 5: Energy AwarenessStep 6: Eliminating Sources of Contamination

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To initiate TPM, the Company and Factory leadership should promote all seven (6 Workshop plus 1 Visual Management) of above steps despite excuses that may come by.


The company can then gradually eliminate the losses without adding Cost and new Equipment reinvestment to establish a more effective relationship between operators and machines to maintain it in the best possible condition.

To implement a current Lean Maintenance System,-Total Productive Maintenance (TPM) by;understanding different types of Maintenance in TPM. synergizing Production & Maintenance Staff working together as a team to Implement TPM for Equipment. Techniques Review and externalize Inspection activities to AM.Establishing a baseline through ‘Clean to Inspect, Inspect to detect and Detect to Correct.’ Implement AM Checklist with TPM Board Visual

Management.

Course Content

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What does Maintenance mean

to you?

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.


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!’.

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Types of Maintenance in TPMAutonomous Maintenance: process by which equipment operators accept and share responsibility (with Maintenance) for the performance and health of their equipment.

Preventive Maintenance: routine maintenance to maintain the basic equipment conditions, replace deteriorating parts, and maintain equipment in on-spec condition. It is carried out at predetermined periods, to ensure equipment reliability.


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Types of Maintenance in TPM

Predictive Maintenance (condition-based): corrects equipment deterioration by condition monitoring and machine diagnosis and helps detect impending problems before they occur.

Breakdown Maintenance (reactive): corrects equipment deterioration after the occurrence of a breakdown.


I run it,you fix it

I fix it,you run it

Autonomous Maintenance is Not,


=

Establish aBaseline

EnergyAwareness

Cleaning is Inspecting

EliminatingContamination

VisualManagement

Equipment /ToolMaintenance

EquipmentLubrication Consumables

Total Productive

MaintenanceWorkshop

(TPM)

TPM the Effective Maintenance 6 Steps# of Autonomous Maintenance Workshop

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Step #1 Establish a Baseline

Establish a baseline on your equipment to determine exactly what condition it is in right now.

A baseline helps guide our improvement activities and provides a starting point from which we can measure our improvements.


The goal is that the asset be reliable, easy to maintain and available when you need it.

Clean to Inspect, Inspect to Detect & Detect to Correct

Q: Do you wash your car by hand or in a car wash?

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To Establish the Baseline Condition of a Used Car

Check for body damage–Look for leaks

Check tire wear–

Observe the gauges–

Listen for vibrations and noises– Check for unusual odors

Check Vibration

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Is the equipment difficult to:

LubricateInspectReachAccessClean

Remove Covers

Establish a Baseline to Determine the Condition of your Equipment.

Is the equipment free of:

Dirt/DustPaint

ChemicalsAir Leaks

SandSteam/Gas Leaks

Process PartsOil/Grease Leaks

Water LeaksCoolant Leaks

Are the following identified?

Safety HazardsLockout Points

Lubrication PointsInspection Points

E-Stop ProceduresStart up and ShutDown Procedures

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Step #2 Initial Cleaning (Cleaning to Inspect)

The goal is to:Provide a clean, efficient, and safe work environment.

Enable you to identify conditions that lead to unexpected breakdowns.

Example: Broken components, fluid leaks, air leaks, etc.

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Step #3 Visual Management for Autonomous Inspection The goal is to:

Add signs, markings, and other visual devices so that normal and abnormal operating conditions are obvious to anyone at a glance.

Enhance the cleaning is inspecting process by identifying correct locations for stored items and tools, and correct quantities of consumables.

Allow for easy identification of safety, quality, environmental, and process abnormalities.

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Visual Management (Identification of Direction)

The goal is to: Add Signs, Arrows, and other

Visual Caption so that Product Quantity, Location and Flow are obvious and able to attract anyone at a glance.

Enhance the retrieval of Parts by identifying Specific location at a logical space for items to be stored.

Allow for fast Visual identification of actual physical quantity of parts.

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Abnormal? Unknown? Normal?

How would you know what the normal operating range is?

How would you know if there were problems developing?

Visual Management (Identification of Norm)

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Visual Management Examples

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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 PRESSURE80-100 psi

#1Main Air Supply

LOCKOUT

Work place Organization Standards ( Visual Management of Equipment) - Color Coding

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Step #4 Equipment Lubrication

The goal is to:Provide guidance in identifying and developing lubrication requirements, routes, and visual cues for the proper lubrication of equipment.

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

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70% of all mechanical equipment failures are a

result of improper lubrication.

Too much lubricant is as bad as too little

SSSSS

Equipment Lubrication

SSSSS

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Example: Bearing Block Lubrication

This picture shows lubrication to only one side

of bearing.

Before After

This picture shows the additional grease fitting, so lubrication can

be done on both sides

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Step #5 Energy Awareness

The goal is to:Identify all sources of energy.

Provide a process to manage energy costs, switching off machines to conserve energy when it is not required.

e

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The Energy commonly used

Water I Electricity

M Natural gas Hydraulics

People

Air/Pneumatic

TInert gases

HGravity

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Step #6 Eliminating sources of Contamination

The goal is to: Permanently eliminate sources of contamination in order to keep equipment clean and damage free.

Simplify equipment for easy and safe cleaning and inspecting of places that are hard to clean, inspect, lubricate, and adjust.

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Source of Contamination (intermittently shorting out the machine)

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Hydraulic Tubes ( Example of two tubes rubbing together)

TPM ImplementationDevelop early equipment management program

The principle of designing the maintenance of Equipment in the prevention of breakdown can be applied to new Products and to new Equipment and existing Machines.


TPM Board & AM Checklist with Visual Management Implementation.

TPM Board,

AM Checklist, Road Map

Autonomous Maintenance Workshop

New products must be designed so that they can be easily produced on new or existing machinesNew machines must be designed for easier operations, changeover and maintenance.

Shop Floor TPM board (Example)

Team D Suggested Layout of Inform ation Board

Suggested Layout of Information Board• Board measures 36X48 mounted -- 40 to 48 inches f rom the floor• Att ach Consumables list to TPM cabinet door• Lockout instructions & map to be loca ted on main electrical cab inet (not on TPM Board)

Lube CriticalCleaning

Route Map

Problem andComponent

Codes

MSS EquipmentProblem Log Sheet

(S.R. Record)

OEE WeeklySummary Sheet

(if Available)

P.M. Schedule

List of personsresponsible for

updating each item onthis board

TPM Information Board

Machine OperatorMachine Name

Operators’ Name(s)

Instructions forLube & Critical

Cleaning

Any Single PointLesson placebehind theseinstructions TPM Management

Walk-throughChecklist

Small GroupActivity

ImprovementItems (form)

Start-up/ShutdownProcess Map on Back

Team D Note:Board construction woodwith cork facing or magnetic

Operator Sign-offSheet (daily)

DAILY AUTONOMOUS MAINTENANCE CHECKLIST Week:

(Performed by Production) Date:

Waterjet

STEP INSPECTION ITEM/S

CONDITION/READI

NG CHECK BY ACM No SHIFT REMARKS

Record Actual (Initiate) D,S,N (Actions taken)

M T W T F S S

Verified by : …………………………. Page 2/3

(Area Manager) file:TPM1 rev c

Date :…………………………..

AM Checklist (Blank)

Waterjet Checklist (Example) WATERJET

STEP INSPECTION ITEM/S

CONDITION/READING

CHECK BY

ACM No SHIFT REMARKS

(Indicate

Actual) (Initiate) D,S,N (Actions taken)

M T W T F S S

1 Robotic panel and computer

Switch on the robotic panel and computer

_Check weather the robotic panel and computer

working properly or not ;

Normal - window screen appear (/)

Abnormal - Call IS technician if the computer screen

not appear (M)

2 Waterjet abrasive bulk

_Check abrasive filter

Normal - (/)

Abnormal - filter damaged (inform Technician) (D)

_Top-up abrasive before start trimming process

Standard 2 bags / shift

_Use vibrator to filter in abrasive into the bulk

_Open compress air valve and open release valve

at a same time.

_Check air regulator

Normal - 4 bar (/)

Verified by : …………………………. Page 1/3

(Area Manager) file:TPM1 rev B

Date :…………………………..

Waterjet Pool

Tank

water jet softerner

Panel

PC Monitor

S# 1

S# 1POU

WorkingTable

S#2

Abrasive bulk tranfer tank

Electrical panel Intensifier pump

Robotic control cabinate

Main Compress air valve

Water inlet valve no1

Water inlet valve no2

Incoming Production

Parts

Problem carts

Incoming Production

Parts

Plywood

WorkingTable

Outgoing Production

PartsWaterjet Route Map

Waterjet Route Map (Example)


Audit, Review & Externalize Inspection Activities from Equipment Manual to Autonomous Maintenance

Put in place TPM Board with Inspection Points & AM Checklist with Visual Management, supporting PM Implementation.

Identify routine Inspection Activities from Equipment Manual to develop AM Checklist for AM Inspection & TPM Board.


Workshop Purpose: to ensure Equipment is in operational condition through routine inspection of parameters before start of operation. to trigger abnormality before damage occur.

to identify Inspection points with Visual Management for ease of Inspection using AM Check List.

Day 2How to Implement Maintenance TPM after (AM)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

Course Content
