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									WHAT IS
 TPM
                            W H A T I S TPM ?


• A well defined methodology to optimize resources
  & improve performance


• A culture change - “never be satisfied”

•   Team-work and cross functionality
•   Transparency and visibility
•   Discipline and rigour
•   Continuous improvement
•   Wireless real time data collection, data mining and data assessment
                          16 MAJOR LOSSES

• TPM is a system to organize practical, shop-floor
  methods to reduce losses ...
EQUIPMENT                        MAN POWER
1- Failure Loss                  10- Motion Loss
2- Start up Loss                 11- Measure & Adjust
3- Speed Loss                    12- Management Loss
4- Set up & Adjustment           13- Line Organisation
5- Idling & Minor Stops          14- Lack of Automation
6- Defects & Rework
7- Shutdown Loss
8- Die, Jig & Tool Loss            MATERIAL
                                   15- NTM, Consumables
 ENERGY
                                   16- Yield Loss
 9- Energy Loss
                                                           16 MAJOR LOSSES


                                                       Man (Man time)       Machine (machine
        Labour efficiency                                                   time)                                 Machine efficiency
                                                        Operational time    Working time

                                                           Man Loading       Machine                      Scheduled Downtime




                                                                                                                                  major losses obstructing
5 major losses obstructing




                                                                  Time       Loading time




                                                                                                                                   equipment efficiency
                                  Production
   manpower efficiency




                                                                      Net
                                                                          Operational
                                  man-hour                   operational
                                                                    time
                                                                          time
                                     loss                           Real Net
                                                               working operational
                                                                    time time
                                                                                                                Downtime loss
                                                                    Value Value
                              Line organisation                    added added
                                                                     time time
                               man-hour loss

                                                                                                               Performance loss
                             Defect in man-hour loss
                                                                                                           Defects quality loss
                                                         Energy                    Material
                                                            Energy input     Material input (number, weight)

                                                         Effective energy    N. quality products
                                                                            Ideal weight
                                                                            of quality
                                                                            products
                   W H A T I S TPM ?




in other words :
INCREASE THE RELIABILITY OF THE PLANT
      TE C H N I Q U E S    o f TPM



- Cleaning
- Tagging
-5S
- Details: 1 / 30 / 300
- Teams
- Loss Deployment
- Audits
- Communication : Boards
- One Point Lessons (OPL)
                    C U L T U R E C H A N G E

                  EXIT THE “QUICK-FIX CULTURE”
Losses



                                              Sporadic loss
                                                               Restoration area
                                                               in order to return to
                                                               previous condition
                                                               “Quick-fix zone”



                                      Objective
                                  Optimal conditions
         Chronic losses              Zero defects




         Innovation area                                Time
           to achieve optimal conditions
        COMPANY LANGUAGES



                   Man (Man time)   Machine (machine
                                    time)
Source : Juran
                        Top Management                     CAN
                        Language                           SPEAK
                                $
                                $                      TPM ALL
                   Middle Management                       COMPANY
                   Language                                LANGUAGES
                 $ AND TECHNICAL


        Junior Management and personnal Language

                 TECHNICAL
                 TPM ORGANISATION

BOARD                                               AM=AUTONOMOUS MANAGEMENT
                     OVERALL
                       Machine (machine
                                                    PM= PROGRESSIVE QUALITY
                     WCMCOORDINATOR                 FI=FOCUSED IMPROVEMENT
                        time)
            Man (Man time)

                                 PLANT WCM
                                 Machine (machine
                                COORDINATOR
                                  time)
   PLANT STEERING                                         AM PILLAR
   COMMITTEE             $
   STRUCTURE                                              PM PILLAR
                                                          FI PILLAR
    DEPARTMENTAL
    COMMITTEE                                             .........
    STRUCTURE

                                                                 AREA
                                                               COMMITTEE
                                                               STRUCTURE

                                                                TPM TEAM
                                                                STRUCTURE
              LOSS DEFINITION




                           Cost that can




                 Losses
                            be attacked
                            Cost that can
Actual Cost
                           not be attacked


                          Cost that
                           Adds
                           Value
                            LOSSES OF UPTIME
                                    LOSSES
                                   OF UPTIME



      AVAILABILITY                PERFORMANCE                         QUALITY
         LOSSES                      LOSSES                            LOSSES


                             SPEED LOSSES       SHORT STOPS



                   START UP
  BREAKDOWNS     SIZE/ BRAND                      DEFECTS             SCRAPS           OVERUSAGE
                   CHANGE

                                   AUTONOMOUS
                                   MANAGEMENT
                                      TEAMS
                                                                         PROGRESSIVE
  PLANNED         FOCUSED                                                  QUALITY
MAINTENANCE    IMPROVEMENT                                                   TEAMS
   TEAMS           TEAMS
                 These teams attack individual loses with different methodologies
                          LOSS DEPLOYEMENT OF UPTIME (OEE)


        Quality Losses:                                                 Waste Losses:
                                                                        Hold Losses:
        Performance Losses:                                             Speed Losses:
                                                                         Short Stops:
        Availibility Losses:
100 %




                                                                         Breakdown
                                                                         Losses:
                               UPTIME



                                                                         Size
                                                                         Brand Change
                                                                         Startup
                                                                         Losses:


                      UPTIME IS AN INDICATION ON ‘’WHAT WE DO GOOD’’
             THE PORTION ABOVE UPTIME THAT SUMS UP TO 100 % SHOWS THE LOSSES
        LOSSES NEEDS TO BE DEFINED AND DEPLOYED SYSTEMATICALLY FOR GOOD ANALYSIS

								
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