F&N DairiesPulau Indah

Klang

TPM Assessment/Implementation

Towards World Class Manufacturing

timothywooi2@gmail.com No part of this training manual may be reproduced.

• Principal Consultant for Lean Management. Certified TPM & Kaizen Specialist with 30 over years

working experience.

• Provides Technical Consulting Services on TPM, Kaizen and Cellular System set up.

• A Mechanical background Green Innovator recycling and reusing Idle resources to eliminate waste to add Value to promote Green.

• Founder of Tim’s Waterfuel, an alternative Hydroxy

Fuel supplement using Water that adds power and reduce Co2 emission on automobiles.

• An NGO Community worker for Prison, Drug

Rehabilitation and CREST North (Crisis Relieve & Training) Malaysia, an organization that respond to Crisis & Flood.

Timothy Wooi

Add: 20C, Taman Bahagia, 06000, Jitra, KedahEmail: timothywooi2@gmail.com

H/p: 019 4514007 (Malaysia)

Introduction

• Yourself • Your name ? • Department / Section

Why are you here?

Parable of the Pencil.

TPM Implementation Planning and Preparation:1. Top management commits to TPM implementation2. Introductory Education and Training3. Establish TPM promotion organization4. Value stream map and select pilot model5. Collect OEE data / Select a Baseline6. Set basic policies and targets7. Create master plan for TPM implementation8. TPM kickoff

Full TPM ImplementationImplementation9. Establish system to improve production efficiency

– Autonomous Maintenance (Workshop)– Kaizen– Planned Maintenance– Skill enhancement– Small Group Activities

10. Early equipment management11. Establish a quality maintenance system12. Improve operation efficiency in the office environment 13. Establish safety, hygiene and working environmental

protection system14. Total application of TPM and raising the level

TPM StrategyDay 1

– Team Charter/ formation and TPM kick-off – Establish TPM policies, TPM schedule steps– Gather Info/data for AM checklist, – Clean n Inspect, Clean, Oil, Dirt

Day 2 – Re access maintenance activities, gather data and validate info for A.M. Check - pictures before. – Identify Improvement Activities

Day 3– Focused Improvements(Kaizen)– Improvement Action Plan-Clean, Dust, Oil – Preparation for Improvement Projects Action List Proposal/AM Training

Day 4– AM Training/Action Implementation– Document Report using standard formats

Day 5– Report Out & Presentation

Day 1 MorningTPM policies,6 Steps to TPM Installation

• Establish basic TPM policies and SMART goals. Analyze the existing conditions and set goals that are SMART.

(Gather Info for AM checklist, Clean n Inspect)

• 6 Steps to TPM Installation (until Clean & Inspect) • TPM kick-off.

Implementation will begin at this stage.

Noon Cleaning and Inspection

• Log Out Tag Out on Machine.

• Actual Cleaning and Inspection of Machine to externalize to Autonomous Maintenance.

Operators routine cleaning and inspection will help

stabilize conditions and stop accelerated deterioration.

(reference Clean & Inspection Checklist for Production Machine)

Day 2 Morning Autonomous maintenance for Operators

• Develop an autonomous maintenance program for Operators.

• Create a DAILY Autonomous Maintenance Checklist, (Use Visual Roadmap/log out tag out procedures/TPM

Board)

Operators routine cleaning and inspection will help stabilize conditions and stop accelerated deterioration. (Reference: AM Cleaning and Inspecting followed by AM Checklist for Printing Machine)

Noon Assessment/Improvements

• Identify problems found during Clean & Inspect.

• Identify Improvements projects for Moonshine activities – improve 5S– Address dust – Oil n Lubrication

(Reference: AM Cleaning and Inspecting followed by AM Checklist for Production Machine)

Day 3 Focused Improvements (KAIZEN)

• Improvement Action Plan-Clean, Dust, Oil Identify causes of Dust and Contamination and

Brainstorm actions to address n prevent occurance

• Preparation for Moonshine Projects Action List Proposal/AM Training

(Use 1H n 4 WHs approach to identify root cause.)

Day 4AM Training and Action Implementation

• AM Training/Action Implementation

• Document Report *

(Use Target & Scope, Before n After Cartoon &Kaizen Newspaper to record activities with Pictures with Road Map & Visual identifications for AM. on TPM Board).

Day 5 Report Out and Presentation

• Report out presentation.

– Objective/Target and Scope– Improvement Cartoon– Kaizen Newspaper– Review

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 institutionalized rework in

your facilities?

Total Productive Maintenance

Why TPM?• TPM combines the traditionally American practice of

Preventive Maintenance with Total Quality Control and Total Employee Involvement, to create a culture in which the user partners with the Maintenance in maintaining the Equipment towards a “ready to use condition” using energy efficiently.

• It is a company-wide team-based effort to build quality into equipment and to improve overall equipment effectiveness

Why Implement TPM?

Cost Reduction for Survival

Strict Quality Demands

World ClassDiversification

of Needs, Shorter Delivery Time

Change Work Environment

Reduce cost dramatically by pursuing the extreme in equipment (production) effectiveness

Establish conditions that will not allow defects and manage conditions that will prevent defects

Create unmanned operations and people friendly working equipment

Minimize machine setup time and get the product to the customer on time World Class Qualifiers

Set-Up and Adjustment

Idling andMinor Stoppage Reduced

Speed

Quality:Defects in Process& Rework

ReducedYield

EquipmentFailures

Easy to measureLow impact on profit

High impacton profits

Labor Materials/spares Outside servicesMaintenance overhead

Equipment Production Losses (Six Big Losses)

Autonomous Maintenance

I run it,you fix it

I fix it,you run it