1.tpm awareness information en

1

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

Welcome To

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


5


The Main objective of TPM is :Zero Interruptions

Zero DefectsZero 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

AUTONOMOUS

MAINTENANCE

QUALITY

MAINTENANCE

PLANNED

MAINTENANCE

INDIVIDUAL

IMPROVEMENT

TRAINING

PEOPLEDEVELO

SAFETY

EHS

EARLY

EQUIP

MANAGEMENT

P

5S´s


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T.P.M.Total Productive Manufacturing

People , Equipment and ProductImprovement by Working Together.

EXCELLENCE


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PLANTOVERVIEW

PLANT

OVERVIEW


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TPMSelf Assessment

PLANT

OVERVIEW

TPMSelf Assessment


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TPM Self AssessmentBackground:

∆1991 First attempt to implement TPM.∆ TPM consultant provides training to selected Managers,Supervisors and Engineers.∆ One coordinator with experience in Process and Maintenanceis assigned to lead TPM.∆ Literature and materials, prepared and distributed.

Lack of support and involvement results on failing theimplementation.


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TPM Self Assessment1996

∆ One Staff Mgr. is assigned to lead the TPM Implementationplant wide.

∆ A core team is formed on 2Q/96 with key people from differentdepartments 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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AsiaBenchmarking

PLANT

OVERVIEW

TPMSelf Assessment

AsiaBenchmarking


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TPM BenchmarkingAsia Facilities

Facility 1 April1996

Facility 2Facility 3

Committee:

Objective:

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

May

June

4 Chosen Folks

Learn from Asia success experiences in TPMimplementation and come up with directions forPlant implementation.

TPM Awareness Information

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Benchmarking Conclusions

Total management involvement.

T.P.M. Manager (dedicated).

A well defined implementation process.

Provide people with time to work on it. ( 4- 6 Hr./wk ).

Each staff has their own T.P.M. Promoter full time.

Focused in Consultant X model.

Focused in just one product line per area.

Budget assigned for consulting and external training.


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TPMPLANT

OVERVIEW

TPMSelf Assessment

AsiaBenchmarking

TPMImplementation


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 THROUGHOUTSHOP FLOOR. ( Autonomous Maintenance, Planned Maintenance etc..)

# ESTABLISH A RELIABILITY AND MAINTAINABILITY SYSTEM TO MAXIMIZEEQUIPMENT 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 SUPPORTT.P.M. GOALS.


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T.P.M. PLANT WIDE STRUCTURE

TPM

T.P.M. Office ResponsiblePlant Manager

5 ´sAutonomousMaintenance

PlannedMaintenance

IndividualImprovement

QualityMaintenance

EarlyEquipment

ManagementSafety

TrainingPeople

Development


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PROMOTION STRUCTURE(OVERLAPPING SMALL GROUPS)

PLANTMANAGER

STAFF MANAGERS

OPERATIONS

TPM PILLARS& PROMOTION

OFFICE

TPMPROMOTERS


DEPARTMENTMANAGERS

DEPARTMENTSUPERVISORS

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.)


B-820

B-609

V-701

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Line and Machine Selection

B-820

Machine 1 Machine 2N-661

POWER

HEATER

Machine 3 Machine 4B-609

V-701


START

TA

TPM Implementation PlanACTIVITIES

DEFINE STRATEGIES

1996 1997 1998 1999 2000Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2

PREPARATION

STAGE

MASTER PLANORGANIZATION

INTRODUCTION TRAININGPUBLICITY

1TPM

2 3

IMPLEMENTA

MODEL MACHINESMachine 1Machine 2Machine 3Machine 4

EXTENDIMPLEMENTATION

SIMILARPRODUCTION LINES

KICK

OFF

AUTONOMOUS MAINTENANCE&

REDUCE 6 BIG LOSSESEXTEND SIMILAR MACHINES

30%to

50%

TION

RGET

COMPLETEIMPLEMENTATIONDEFINED AREAS

100%

TPM 90 Days Explosion PlanOctober November December

ww40 ww41 ww42 ww43 ww44 ww45 ww46 ww47 ww48 ww49 ww50 ww51 ww52Machine 1

PILOT TEAM Step 3Planned maintenance

6 big lossesIndividual Improvement

Start

StartStart

Start10 Extension teams19 Extension teams

step 1-2Start step 1

4 mc7 mc

3 mc6 mc

3 mc6 mc

Machine 2PILOT TEAM Step 2-3

Planned maintenanceStart

Start6 big losses

Individual ImprovementStep 1 Step 2

Step 111 Extension teams step 1-2 B-613 3 mc 2 mc 2 mc B-601 L-604

Machine 3PILOT TEAM Step 2-3

Planned maintenance6 big losses

Individual ImprovementStart

Start

Start

Start

6 Extension teams2 Extension teams

Machine 4PILOT TEAM

step 1-2Start step 1

Step 1-2

Start

Start

2 mc 4 mc

Planned maintenance6 big losses

Individual ImprovementStart

Start

Start4 extension teams Start step 1 a-820 a-821 J-701 J-601

PILLARS IMPLEMENTATION MODELGANTT

TPM Activity Board Extension TeamsServer Data collection M1 M2 M3 M4

GM AuditTeam presentationsTPM Office AuditConsultant visitTPM MeetingLocal BOOT CAMPTPM MCOE MEETING, JAPANPillars meeting

M

CO

DENIAL

M

MEN

T

T

I

RESISTANCE

EXPLORATION

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T.P.M. TRANSITION CURVEPOLICIES DEVELOPMENTT.P.M. PROMOTION OFFICE START

MANAGEMENT MACHINESFOCUS IN FEW EQUIPMENT

T.P.M. PROMOTION DELEGATIONINCLUDE T.P.M. IN PERFORMANCEMANAGEMENT PLAN.INCLUDE T.P.M. IN JOB

KICK OFF

FOCUS TRAININGSUCCESS STORIES5 S´s

CONSULTANTIN

DESCRIPTION.ACCELERATEDDEPLOYMENT.

CONSULTANTOUT

DEVELOP DATA COLLECTION SYSTEMATTENTION TO FOCUS TEAMSTRAINING DEPLOYMENTIMPLEMENTATION PLANRESOURCE IMPLEMENTATION

GOALS SETTING FORALL ORGANIZATION.

LOOK FOR ADDITIONAL WAYSTO DEPLOY T.P.M.

FINISH CONFLICT WITH THE CULTUREORGANIZATION ALIGNMENTREWARD SYSTEMCONTROL CHAOS


2X

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KEY GOALS

1.- TOTAL EQUIPMENT EFFECTIVENESSA) Equipment BreakdownB) M.T.B.A.C) M.T.B.F.

2.- REJECT CAUSED BY LINE EQUIPMENT

3.- LINE REJECT RATE

4.- CYCLE TIME

5.- FATAL ERROR AT CUSTOMER

6.- ON TIME DELIVERED

7.- MANUFACTURING COST

%HOURS/MONTHMINUTESHOURS

PPM

%

DAYS

# OF

%

USD

851/101x10x1x2x

1/5

1/5

0.8X

0

98

20% LESS

8.- LABOR PRODUCTIVITY


K.UNITS /# OF D/L


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AUTONOMOUS MAINTENANCE.

MANUFACTURING SPECIALIST


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AUTONOMOUS MAINTENANCE IS:

Maintenance performed by equipment operators.

THE FIRST 3 STEPS OFAUTONOMOUS MAINTENANCE.

STEP # 1 INITIAL CLEANING.

STEP # 2 COUNTERMEASURES FOR THE CAUSESOF FORCED DETERIORATION AND IMPROVINGHARD-TO-ACCESS AREAS.

STEP # 3 MAKING A TENTATIVE CLEANING/LUBRICATION STANDARD.


3

7

2

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AUTONOMOUSMAINTENANCE

5

4

Selection

Formats:Daily Cleaning &Initial InspectionHot Spots, CAP-DO5W´s Develop One

Major Problems Point lesson

6

Put F Tags

Step # 1

Initial Cleaning

StandardizationCleaning /Lubrication

Initial Cleaning(Inspection)

Training inOne Point Lesson

Photos BeforePhotos After

1

8


3 7

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Courtesy, in part, of Motorola SPS.


5

Thank You!

4

Put “F” Tags

Failures AnalysisWhy´s Analysis

Actions inSources ofContamination &Hard access areas

Step # 2

6

Find & ListAreas of HardAccess

Sources ofContamination &

Hard Access Areas

Modify Covers ForEasy Visualization

& QuickDisassemble

Find & ListSources ofContamination Remove “F” Tags


2 Initial InspectionFinal Inspection

(Audit)

1


8

46

373

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Courtesy, in part, of Motorola SPS.


5

Thank You!

Verifyactual time

Improve time ofexecution

Detailactivities

Vs estimated

Put “F” Tags(Establish time& frequency)

Step # 3TentativeStandards

Remove“F” Tags

Cleaning / Lubricationimplementation Apply activities to

similar machines

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Develop tentativestandards 8

1


443427

12

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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:

284126

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PLANT

OVERVIEW

TPMSelf Assessment

AsiaBenchmarking

TPMImplementation

Expansion Plan


Expansion Plan


1998

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T.P.M. DEPLOYMENT

LINE

FLOW

CURRENT EQUIPMENT IN T.P.M.

SAME KIND OF EQUIPMENT

1999/2000 EXPANSION

1997


Line

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PROJECTED PROGRESS IN TEAMS Q-1’ 98

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

Wafer ProcessLine 1

Line 2

Line 3

Line 4


11

03

03

04


16

11

08

01

03

01

01

01

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T.P.M. FOLLOW-UP

TEAMSPRESENTATION

TEAMSAUDITS

TEAMSMEETING

Consultant X MANAGERSVISITS PRESENTATION

6 TEAMS

PER

MONTH

6 TEAMS

PER

MONTH

WEEKLY TWO DAY

EVERY

TWO

MONTHLY

MEETING

MONTHS


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PLANT

OVERVIEW

TPMSelf Assessment

AsiaBenchmarking

TPMImplementation

Expansion Plan

Pilot TeamCase Study


Pilot TeamCase Study


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PILOT MACHINE

N-62361


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Defectives30

25

20

23

20

25

22

1820

21

1719

23

15

10

55

78

65

9

6

3 4 3 32

4

6

8

65

4

76

0N-662361 N-61162 N-634766

JAN 96JUN

FEBJUL

MARAUG

APRSEP

MAYOCT 96


%T.C.

ENE./96MAR MAY JUL

OCT./96ABR

%T.C.

ABR

AGO

ENE./96AGOMAR MAY SEPFEB JUN JUL

SEPFEB JUN

OCT./96

%T.C.

FEB JUN AGOMAROCT./96ENE./96

MAYABR JUL SEP

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DOWN TIME25%

23% 23%

20% 20% 20%

N-66236115%

10%

17%18%

12%

15%

18% 18%

5%

0%

25%

20%

N-66324215%

10%

5%

12%11%

10%11%

8%9%

7%6%

8%10%

0%

25,00%

20,00%

15,00%

N-649666 10,00%

5,00%7,50% 8%

4%

7%9%

5%3%

5% 6%8%

0,00%


42


CLEANING IS INSPECTION....

5’S

AUTONOMOUS

MAINTENANCE


43


INSPECTION IS DETECTION.

CRASH

Broken Part


44


PRESSURECORRECT

INCORRECT

TO MUCHPRESSURE

CORRECT

GAUGE

ALIGNMENT

INCORRECT

NO


45


CORRECT CENTERING

INCORRECT

Dummy Part

CORRECT

SYMMETRY


INCORRECT

BENT

46


CONTACT

CORRECTINCORRECT


47


TO STANDARDIZE AND

PREVENT RECURRENCE

One Point Lesson


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MACHINEPERFORMANCE


Abr MayOct-96Sep-96 Dec-96Jan-97

AgoMarFeb Jun Jul

%D.T.

Nov-96Apr May

Dec-96 Jan-97Feb

Oct-96Mar Aug SepJun Jul

Sep

49


Defectives25

20

15

23

18

“ZERO”

1010

6

Defectives

5 3

12

0 0 0 0 00

25%

20%18%

DOWN TIME

20%

P.C. BOARDDAMAGED

15% 15%

12%10%

5%

9%8%

7%5%

6%4%

3% 3%0%


3

50


WHAT IS NEXT?

6 Big

LINK Losses

44

AutonomousMaintenance

Planned

Maintenance


51



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1.tpm awareness information en