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Welcome To
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TPM Awareness Information
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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.
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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
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T.P.M. = Medical Science of Equipment
PRODUCTION
Foton
AUTOMATION
B-820
VIDEO-AUTO DIE-BONDER MODEL 8030A
POWER
HEATER
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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
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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
M
A
I
N
T
E
N
A
N
C
E
P
L
A
N
N
E
D
M
A
I
N
T
E
N
A
N
C
E
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
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T.P.M.
Total Productive Manufacturing
People , Equipment and Product
Improvement by Working Together.
EXCELLENCE
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PLANT
OVERVIEW
PLANT
OVERVIEW
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TPM
Self Assessment
PLANT
OVERVIEW
TPM
Self Assessment
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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.
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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.
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Asia
Benchmarking
PLANT
OVERVIEW
TPM
Self Assessment
Asia
Benchmarking
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TPM Benchmarking
Asia Facilities
Facility 1
Facility 2
Facility 3
Committee:
Objective:
Cayman Systems USA 513 777-3394
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1996
April
May
June
4 Chosen Folks
Learn from Asia success experiences in TPM
implementation and come up with directions for
Plant implementation.
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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.
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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
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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.
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T.P.M. PLANT WIDE STRUCTURE
TPM
Responsible
Plant Manager
T.P.M. Office
5 ´s
Quality
Maintenance
Cayman Systems USA 513 777-3394
©1998 Revision A 980810
Autonomous
Maintenance
Early
Equipment
Management
Planned
Maintenance
Safety
TPM Awareness Information
Individual
Improvement
Training
People
Development
18
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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.)
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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
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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
Cayman Systems USA 513 777-3394
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R
E
S
I
S
T
A
N
C
E
E
X
P
L
O
R
A
T
I
O
N
TPM Awareness Information
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
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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
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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.
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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:
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126
44
34
27
1
2
24
33
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PLANT
OVERVIEW
Expansion Plan
TPM
Self Assessment
Asia
Benchmarking
TPM
Implementation
Expansion Plan
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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
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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
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TPM Awareness Information
Consultant X MANAGERS
VISITS
PRESENTATION
TWO DAY
EVERY
TWO
MONTHS
MONTHLY
MEETING
37
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PLANT
OVERVIEW
TPM
Self Assessment
Asia
Benchmarking
Pilot Team
Case Study
TPM
Implementation
Expansion Plan
Pilot Team
Case Study
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PILOT MACHINE
N-62361
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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
Cayman Systems USA 513 777-3394
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FEB
JUL
N-61162
MAR
AUG
N-634766
APR
SEP
TPM Awareness Information
MAY
OCT 96
40
% T. C.
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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%
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CLEANING IS INSPECTION....
5’S
AUTONOMOUS
MAINTENANCE
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INSPECTION IS DETECTION.
CRASH
Broken Part
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PRESSURE
CORRECT
INCORRECT
TO
TO MUCH
MUCH
PRESSURE
PRESSURE
CORRECT
ALIGNMENT
INCORRECT
GAUGE
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CORRECT
CENTERING
INCORRECT
Dummy Part
CORRECT
SYMMETRY
INCORRECT
BENT
BENT
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CONTACT
CORRECT
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TPM Awareness Information
INCORRECT
46
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TO STANDARDIZE AND
PREVENT RECURRENCE
One Point Lesson
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MACHINE
PERFORMANCE
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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%
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WHAT IS NEXT?
6 Big
Losses
LINK
4
Autonomous
Maintenance
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4
Planned
Maintenance
50
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