TPM

Courtesy, in part, of Motorola SPS. Thank You!

Welcome To

Cayman Systems USA 513 777-3394 ©1998 Revision A 980810

TPM Awareness Information

1


About T.P.M. After World War ll. Japanese industries determined that to complete successfully in the world market they had to improve the quality of their products. to do so, they imported management and manufacturing techniques from United States and adapted them to their circumstances. Subsequently, their products became known throughout the world for their superior quality, focusing world attention on Japanese- style management techniques. TPM DEVELOPMENT PROGRAM Implementing Total Productive Maintenance Seiichi Nakajima.



2


WHAT IS T.P.M. ?? Definition of T.P.M : T.P.M. IS: A PRODUCTIVE MANUFACTURING SYSTEM with the TOTAL Participation of: Managers, Supervisors, Engineers, Technicians and Operators. T.P.M. Includes the Following Benefits: • Maximize Overall Equipment Effectiveness • Establishment a Complete System of Maintenance for the Machine Entire Life • Create a Better Work Environment, Promoting the Participation for All Employees



3


T.P.M. = Medical Science of Equipment

PRODUCTION

Foton

AUTOMATION

B-820

VIDEO-AUTO DIE-BONDER MODEL 8030A

POWER HEATER



4


The Main objective of TPM is : Zero Interruptions Zero Defects Zero Accidents Throughout total employees participation from Top Management to Operators, based in the following activities:

Autonomous Maintenance • Planned Maintenance • Individual Improvement • Quality Maintenance • Early Equipment Management • Education/Training (People Development) • Safety



5


PILLARS OF TPM A U T O N O M O U S

M A I N T E N A N C E

Q U A L I T Y


P L A N N E D


I N D I V I D U A L

I M P R O V E M E N T

T R A I N I N G

P E O P L E D E V E L O P

S A F E T Y

E H S

E A R L Y E Q U I P

M A N A G E M E N T

5S´s



6


T.P.M. Total Productive Manufacturing People , Equipment and Product Improvement by Working Together.

EXCELLENCE



7


PLANT OVERVIEW PLANT OVERVIEW



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TPM Self Assessment PLANT OVERVIEW

TPM Self Assessment



9


TPM Self Assessment Background:

∆1991 First attempt to implement TPM.

∆ TPM consultant provides training to selected Managers,

Supervisors and Engineers. ∆ One coordinator with experience in Process and Maintenance is assigned to lead TPM. ∆ Literature and materials, prepared and distributed.

ð Lack of support and involvement results on failing the implementation. Cayman Systems USA 513 777-3394 ©1998 Revision A 980810


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TPM Self Assessment 1996

∆ One Staff Mgr. is assigned to lead the TPM Implementation ∆ ∆ ∆ ∆ ∆

plant wide. A core team is formed on 2Q/96 with key people from different departments to coordinate the implementation. Model equipment is selected based on bottle neck operation. Equipment conditions analysis performed. Most of the teams cover the initial cleaning. Activities are focused on six big losses detected and 5 S´s implementation.



11


Asia Benchmarking PLANT OVERVIEW

TPM Self Assessment

Asia Benchmarking



12


TPM Benchmarking Asia Facilities Facility 1 Facility 2 Facility 3 Committee: Objective:


1996 April May June

4 Chosen Folks Learn from Asia success experiences in TPM implementation and come up with directions for Plant implementation.


13


Benchmarking Conclusions Ø Total management involvement.

Ø T.P.M. Manager (dedicated). Ø A well defined implementation process. Ø Provide people with time to work on it. ( 4- 6 Hr./wk ). Ø Each staff has their own T.P.M. Promoter full time. Ø Focused in Consultant X model. Ø Focused in just one product line per area. Ø Budget assigned for consulting and external training.



14


PLANT OVERVIEW

TPM Implementation

TPM Self Assessment

Asia Benchmarking

TPM Implementation



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IMPLEMENTATION/CONSULTANT

* Q3 1996, Consultant X is selected to be Consultant. * Training of Managers, Team leaders and Team members * Master Plan Defined * TPM. implementation initiated according to Consultant X recommendations



16


T.P.M. POLICY # ESTABLISH AN INTEGRATED STRUCTURE TO PROMOTE T.P.M. AS A COMPANY CULTURE. # MAXIMIZE OVERALL EQUIPMENT EFFECTIVENESS # TOTAL EMPLOYEE INVOLVEMENT. # CULTIVATE EQUIPMENT & PROCESS RELATED EXPERTISE THROUGHOUT SHOP FLOOR. ( Autonomous Maintenance, Planned Maintenance etc..) # ESTABLISH A RELIABILITY AND MAINTAINABILITY SYSTEM TO MAXIMIZE EQUIPMENT LIFE TIME. (Planned Maintenance Autonomous Maintenance, Individual Improvement, Early Equipment Management.) # ALL EMPLOYEES MUST PARTICIPATE IN T.P.M TRAINING PROGRAM. # ALL AREAS MUST FOLLOW T.P.M. ESTABLISHED GUIDE LINES. # DEPARTMENT HEAD IS RESPONSIBLE TO ACCOMPLISH AND SUPPORT T.P.M. GOALS. Cayman Systems USA 513 777-3394 ©1998 Revision A 980810


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T.P.M. PLANT WIDE STRUCTURE TPM Responsible Plant Manager

T.P.M. Office

5 ´s

Quality Maintenance


Autonomous Maintenance Early Equipment Management

Planned Maintenance

Safety


Individual Improvement

Training People Development

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PROMOTION STRUCTURE (OVERLAPPING SMALL GROUPS)

PLANT MANAGER STAFF MANAGERS OPERATIONS TPM PILLARS & PROMOTION OFFICE

DEPARTMENT MANAGERS DEPARTMENT SUPERVISORS

TPM PROMOTERS

TPM TEAM



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VISION STATEMENT: TPM PLANT WIDE IMPLEMENTATION

Q1 2000



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T.P.M. IMPLEMENTATION ACTIVITIES MANAGER TEAMS



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PREPARATION / PLANNING STAGE # DEFINE PILOT LINES # AMOUNT OF MACHINES INCLUDED PER LINE # DEFINE CORE TEAM MEMBERS OF EACH LINE # SELECT TEAM MEMBERS PER MACHINE # START ACTIVITIES IN PILOT MACHINES (bottle neck.)



22


Line and Machine Selection

B-820 B-820

Machine 1

Machine 2 N-661

POWER HEATER

Machine 3

Machine 4 B-609 B-609

V-701 V-701



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TPM Implementation Plan ACTIVITIES DEFINE STRATEGIES MASTER PLAN PREPARATION ORGANIZATION STAGE INTRODUCTION TRAINING PUBLICITY

I M P L E M E N T A T I O N

S T A R T

T A R G E T

MODEL MACHINES Machine 1 Machine 2 Machine 3 Machine 4 EXTEND IMPLEMENTATION SIMILAR PRODUCTION LINES COMPLETE IMPLEMENTATION DEFINED AREAS

1996

1997

1998

1999

Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2

1

T P M K I C K O F F

2

2000

Q3 Q4 Q1 Q2

3

AUTONOMOUS MAINTENANCE & REDUCE 6 BIG LOSSES EXTEND SIMILAR MACHINES

30% to 50%

100%

TPM 90 Days Explosion Plan October

November

December

ww40 ww41 ww42 ww43 ww44 ww45 ww46 ww47 ww48 ww49 ww50 ww51 ww52 Machine 1 PILOT TEAM

PILLARS

Step 3 Planned maintenance 6 big losses Individual Improvement 10 Extension teams step 1-2 19 Extension teams Start step 1 Machine 2 PILOT TEAM Step 2-3 Planned maintenance 6 big losses Individual Improvement 11 Extension teams step 1-2 Machine 3 PILOT TEAM Step 2-3 Planned maintenance 6 big losses Individual Improvement 6 Extension teams step 1-2 2 Extension teams Start step 1 Machine 4 PILOT TEAM Step 1-2 Planned maintenance 6 big losses Individual Improvement 4 extension teams Start step 1 IMPLEMENTATION MODEL GANTT TPM Activity Board Extension Teams Server Data collection GM Audit Team presentations TPM Office Audit Consultant visit TPM Meeting Local BOOT CAMP TPM MCOE MEETING, JAPAN Pillars meeting

Start Start Start Start 4 mc 7 mc

3 mc 6 mc

3 mc 6 mc

Start Start Step 1

Step 2 B-613

3 mc

Step 1 2 mc 2 mc

B-601

L-604

Start Start Start Start 2 mc

Start

4 mc

Start Start Start Start a-820 a-821 J-701 J-601

M1

M2

M3

M4


T.P.M. TRANSITION CURVE

D E N I A L

POLICIES DEVELOPMENT T.P.M. PROMOTION OFFICE START MANAGEMENT MACHINES FOCUS IN FEW EQUIPMENT FOCUS TRAINING SUCCESS STORIES 5 S´s

T.P.M. PROMOTION DELEGATION INCLUDE T.P.M. IN PERFORMANCE MANAGEMENT PLAN. INCLUDE T.P.M. IN JOB DESCRIPTION. ACCELERATED DEPLOYMENT.

CONSULTANT IN

CONSULTANT OUT

KICK OFF

DEVELOP DATA COLLECTION SYSTEM ATTENTION TO FOCUS TEAMS TRAINING DEPLOYMENT IMPLEMENTATION PLAN RESOURCE IMPLEMENTATION


R E S I S T A N C E

E X P L O R A T I O N


C O M M I T M E N T

GOALS SETTING FOR ALL ORGANIZATION. LOOK FOR ADDITIONAL WAYS TO DEPLOY T.P.M. FINISH CONFLICT WITH THE CULTURE ORGANIZATION ALIGNMENT REWARD SYSTEM CONTROL CHAOS

26


KEY GOALS 1.- TOTAL EQUIPMENT EFFECTIVENESS A) Equipment Breakdown B) M.T.B.A. C) M.T.B.F.

% HOURS/MONTH MINUTES HOURS

85 1/10 1x10x 1x2x

2.- REJECT CAUSED BY LINE EQUIPMENT

PPM

1/5

%

1/5

3.- LINE REJECT RATE 4.- CYCLE TIME

DAYS

0.8X

5.- FATAL ERROR AT CUSTOMER

# OF

0

6.- ON TIME DELIVERED

%

98

7.- MANUFACTURING COST

USD

20% LESS

8.- LABOR PRODUCTIVITY

K.UNITS /# OF D/L

2X



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AUTONOMOUS MAINTENANCE.

MANUFACTURING SPECIALIST



28


AUTONOMOUS MAINTENANCE IS: Maintenance performed by equipment operators. THE FIRST 3 STEPS OF AUTONOMOUS MAINTENANCE. STEP # 1 INITIAL CLEANING.

STEP # 2 COUNTERMEASURES FOR THE CAUSES OF FORCED DETERIORATION AND IMPROVING HARD-TO-ACCESS AREAS. STEP # 3 MAKING A TENTATIVE CLEANING/ LUBRICATION STANDARD. Cayman Systems USA 513 777-3394 ©1998 Revision A 980810


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AUTONOMOUS MAINTENANCE 5 Formats: 6 Daily Cleaning & Initial Inspection 4 Hot Spots, CAP-DO 5W´s Develop One Point lesson Major Problems Selection

Step # 1 3

Put F Tags

Initial Cleaning

Standardization Cleaning / Lubrication

7

Training in One Point Lesson

Initial Cleaning (Inspection)

8 2

Photos Before Photos After

1



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AUTONOMOUS MAINTENANCE 5 Failures Analysis Why´s Analysis

4 Put “F” Tags

6

Actions in Sources of Contamination & Hard access areas

Step # 2 3

Find & List Areas of Hard Access

Sources of Contamination & Hard Access Areas

Find & List Sources of Contamination

2

Modify Covers For Easy Visualization & Quick Disassemble

7

Remove “F” Tags Initial Inspection Final Inspection (Audit)

8

1



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AUTONOMOUS MAINTENANCE 5

4

Improve time of execution

Verify actual time Vs estimated

3

Put “F” Tags (Establish time & frequency) 3

2

Detail activities

Step # 3 Tentative Standards

Cleaning / Lubrication implementation 2

6

Remove “F” Tags

7

Apply activities to similar machines

Develop tentative standards

8

1



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TPM Teams Status October 1997

•Number of Hot Spots detected: •Number of Hot Spots solved: •One Point Lesson developed: •One Point Lesson Taught: •Number of teams on TPM: •Teams on step 3: •Teams on step 2: •Teams on step 1: Cayman Systems USA 513 777-3394 ©1998 Revision A 980810


284 126 44 34 27 1 2 24 33


PLANT OVERVIEW

Expansion Plan

TPM Self Assessment

Asia Benchmarking

TPM Implementation

Expansion Plan



34


T.P.M. DEPLOYMENT

L I N E F L O W

CURRENT EQUIPMENT IN T.P.M. SAME KIND OF EQUIPMENT

1 9 9 8

1997

1999/2000 EXPANSION Cayman Systems USA 513 777-3394 ©1998 Revision A 980810


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PROJECTED PROGRESS IN TEAMS Line Wafer Process Line 1

Q-1’ 98

A.M. STEP # 1 A.M. STEP # 2 A.M. STEP # 3 11

16

03

Line 2

03

11

01

Line 3

03

08

01

Line 4

04

01

01



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T.P.M. FOLLOW-UP

TEAMS PRESENTATION

TEAMS AUDITS

TEAMS MEETING

6 TEAMS

6 TEAMS

WEEKLY

PER

PER

MONTH

MONTH



Consultant X MANAGERS VISITS PRESENTATION

TWO DAY EVERY TWO MONTHS

MONTHLY MEETING

37


PLANT OVERVIEW

TPM Self Assessment

Asia Benchmarking

Pilot Team Case Study

TPM Implementation

Expansion Plan

Pilot Team Case Study



38


PILOT MACHINE

N-62361



39


Defectives 30 25 20

25 23

23

22 20

20

21

18

19 17

15 10

7 5

5

9

8 6

5

8 6

6 3

4

3

3

6

4

7 5

6

4

2

0 N-662361 JAN 96 JUN


FEB JUL

N-61162 MAR AUG

N-634766 APR SEP


MAY OCT 96

40

% T. C.

Courtesy, in part, of Motorola SPS. Thank You! SEP

AGO

JUL

JUN

MAY

ABR

MAR 18%

17%

23%

20% 18%

18%

15%

15%

N-662361

23%

20%

OCT./96

20%

FEB

25%

ENE./96

DOWN TIME

12%

10% 5%

OCT./96

SEP

AGO

JUL

JUN

MAY

ABR

MAR

ENE./96

25%

FEB

% T. C.

0%

20%

N-663242

15% 12%

10%

11%

10%

11% 8%

10%

9% 7%

5%

8% 6%

OCT./96

SEP

AGO

JUL

JUN

MAY

ABR

MAR

ENE./96

25,00%

FEB

% T. C.

0%

20,00% 15,00%

N-649666

10,00% 7,50%

5,00%

9%

8%

8%

7% 4%

5%

5%

6%

3%

0,00%



41


CLEANING IS INSPECTION....

5’S AUTONOMOUS MAINTENANCE



42


INSPECTION IS DETECTION.

CRASH

Broken Part



43


PRESSURE CORRECT

INCORRECT

TO TO MUCH MUCH PRESSURE PRESSURE

CORRECT

ALIGNMENT INCORRECT

GAUGE



NO

44


CORRECT

CENTERING INCORRECT

Dummy Part

CORRECT

SYMMETRY

INCORRECT

BENT BENT



45


CONTACT

CORRECT



INCORRECT

46


TO STANDARDIZE AND PREVENT RECURRENCE

One Point Lesson



47


MACHINE PERFORMANCE



48


Defectives 25

23

20

18

“ZERO”

15

May

Jun

Jul

Ago

Sep

Abr

Mar

Feb

Jan-97

Dec-96

Oct-96

Sep-96

10

Defectives

10

0

0

0

0

0

6

5

3 1

2

0

P.C. BOARD DAMAGED

% D.T.

DOWN TIME

15%

Sep

Aug

Jul

Jun

20%

May

Apr

Mar

Feb

Jan-97

Dec-96

18%

Nov-96

20%

Oct-96

25%

15% 12%

10% 5%

9%

8%

7% 5%

6% 4%

3%

3%

0%



49


WHAT IS NEXT? 6 Big Losses

LINK

4

Autonomous Maintenance



3

4

Planned Maintenance

50




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