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Transcript of Companies Fail in TPM Execution - tpmquality.comTPM,+OEE... · How TPM Pillars Are Linked 5 Planned...
TPM, OEE, Total Productive TPM, OEE, Total Productive TPM, OEE, Total Productive TPM, OEE, Total Productive Maintenance Implementation.Maintenance Implementation.Maintenance Implementation.Maintenance Implementation.
Why Lots of Companies Fail During TPM Execution (36 slides)Why Lots of Companies Fail During TPM Execution (36 slides)Why Lots of Companies Fail During TPM Execution (36 slides)Why Lots of Companies Fail During TPM Execution (36 slides)
Skype contact moses.tan70 Email: [email protected]; [email protected] +65 93213555 - ZenPower International, Singapore
Professor, University of Glasgow, UK
Companies Fail in TPM Execution Companies Fail in TPM Execution Companies Fail in TPM Execution Companies Fail in TPM Execution When They Not Clear About... When They Not Clear About... When They Not Clear About... When They Not Clear About...
(1) TPM Pillar Details & linkages(1) TPM Pillar Details & linkages(1) TPM Pillar Details & linkages(1) TPM Pillar Details & linkages(2) TPM & the Maintenance Dept. Function(2) TPM & the Maintenance Dept. Function(2) TPM & the Maintenance Dept. Function(2) TPM & the Maintenance Dept. Function
(3) Company Priority / resources (3) Company Priority / resources (3) Company Priority / resources (3) Company Priority / resources
Four Core Pillars
Zero BDsZero Defects
Highest OEE / Lowest Product Cost (Zero-Loss / Ideal Cost)
Companies Fail when They don't Companies Fail when They don't Companies Fail when They don't Companies Fail when They don't . . . . Understand TPM's Understand TPM's Understand TPM's Understand TPM's Three KEY Three KEY Three KEY Three KEY . . . . BeliefsBeliefsBeliefsBeliefs1.1.1.1. Every breakdown and defect is due to a Every breakdown and defect is due to a Every breakdown and defect is due to a Every breakdown and defect is due to a deviationdeviationdeviationdeviation . . . . from the required Basic Machine Conditions from the required Basic Machine Conditions from the required Basic Machine Conditions from the required Basic Machine Conditions –––– . . . . Cleanliness, Lubrication, Proper Bolting, Cleanliness, Lubrication, Proper Bolting, Cleanliness, Lubrication, Proper Bolting, Cleanliness, Lubrication, Proper Bolting, Lifespan Lifespan Lifespan Lifespan . . . . Inspection and Inspection and Inspection and Inspection and Part Part Part Part Precision.Precision.Precision.Precision.
2.2.2.2. EEEEvery very very very deviationdeviationdeviationdeviation is due to a is due to a is due to a is due to a Man-Man-Man-Man-MistakeMistakeMistakeMistake and are and are and are and are .... preventable by preventable by preventable by preventable by Mistake-proofingMistake-proofingMistake-proofingMistake-proofing (Poka-Yoke). (Poka-Yoke). (Poka-Yoke). (Poka-Yoke).
� Manufacturing Excellence is sustained by building a Manufacturing Excellence is sustained by building a Manufacturing Excellence is sustained by building a Manufacturing Excellence is sustained by building a . . . . CI CI CI CI ....Knowledge BankKnowledge BankKnowledge BankKnowledge Bank to to to to revise the PMrevise the PMrevise the PMrevise the PM shut-down Job-shut-down Job-shut-down Job-shut-down Job- . . . . listlistlistlist and and and and shared shared shared shared totototo AM activities AM activities AM activities AM activities.... 3
How TPM Pillars Are Linked
5
Planned Maintenance ( Zero BDs )
Quality Maintenance (Zero Defects )(Poka Yoke)
Autonomous Maintenance Pillar (eyes, ears,hands helping Maint)
Maintenance Knowledge bankMaintenance Knowledge bankMaintenance Knowledge bankMaintenance Knowledge bank
Focused Improvement(100% OEE) (Cost Reduction)
Enhanced PM Joblist for Maintenance Department
6
TPM End-State GoalsTPM End-State GoalsTPM End-State GoalsTPM End-State Goals
BeforeBeforeBeforeBefore: : : :
“X” Shut-Down PM Job-List
After: New After: New After: New After: New
Revised Revised Revised Revised “X” Shut-Down PM Job-list.
Autonomous Maintenance
---- All other Pillars contributions All other Pillars contributions All other Pillars contributions All other Pillars contributions
---- Improved OEE ( BD, DefImproved OEE ( BD, DefImproved OEE ( BD, DefImproved OEE ( BD, Defects.ects.ects.ects.....Jams, Jams, Jams, Jams, Setup, Speed, Startup and Setup, Speed, Startup and Setup, Speed, Startup and Setup, Speed, Startup and ....Blade-Blade-Blade-Blade-change losses) .change losses) .change losses) .change losses) .
From AM3: Initial Maintenance Standards (Knowledge-Bank) From AM3: Initial Maintenance Standards (Knowledge-Bank) From AM3: Initial Maintenance Standards (Knowledge-Bank) From AM3: Initial Maintenance Standards (Knowledge-Bank)
Model Machine
Current PM Job-list Items
Current Items that Need Revision of Stds
New items to be added to PM Job-list
Current PM Job-list items that are OK
NEW PM Job-list items (Total QTY)
AM3 final recommended list
FPP Bagging
36 items 16 44 20 80 items 49 items
NPP Extruder
22 items 4 51 18 73 items 19 items
Enhanced Enhanced Enhanced Enhanced PM Joblist PM Joblist PM Joblist PM Joblist ((((At End of At End of At End of At End of AMAMAMAM Step Step Step Step 3) 3) 3) 3) Real SampleReal SampleReal SampleReal Sample
FM FM FM FM PacPacPacPackkkkGND GND GND GND CutCutCutCut
8
AM Step-by-Step Audit StandardsStep # Step Goal Activity Pass-Standard.Step # Step Goal Activity Pass-Standard.Step # Step Goal Activity Pass-Standard.Step # Step Goal Activity Pass-Standard.
Step 0 Prepare F-Tagging Map Grasp the current Machine F-Map (what/where)Step 0 Prepare F-Tagging Map Grasp the current Machine F-Map (what/where)Step 0 Prepare F-Tagging Map Grasp the current Machine F-Map (what/where)Step 0 Prepare F-Tagging Map Grasp the current Machine F-Map (what/where) Breakdown history Breakdown history Breakdown history Breakdown history
Step-1 Restoration Cleaning & Inspection => 85% repair rateStep-1 Restoration Cleaning & Inspection => 85% repair rateStep-1 Restoration Cleaning & Inspection => 85% repair rateStep-1 Restoration Cleaning & Inspection => 85% repair rate Step-2a Eliminate Sources of KaiStep-2a Eliminate Sources of KaiStep-2a Eliminate Sources of KaiStep-2a Eliminate Sources of Kai’’’’zen improvements =>70% effective effort tozen improvements =>70% effective effort tozen improvements =>70% effective effort tozen improvements =>70% effective effort to Contamination reduce Contamination. Contamination reduce Contamination. Contamination reduce Contamination. Contamination reduce Contamination.
Step-2b Improve Equipment KaiStep-2b Improve Equipment KaiStep-2b Improve Equipment KaiStep-2b Improve Equipment Kai’’’’zen improvements =>70% effective effort tozen improvements =>70% effective effort tozen improvements =>70% effective effort tozen improvements =>70% effective effort to Accessibility improve Accessibility. Accessibility improve Accessibility. Accessibility improve Accessibility. Accessibility improve Accessibility. Step-3 Initial Maintenance Stds. Equipment-knowledgeable =>50% reduced Sudden Step-3 Initial Maintenance Stds. Equipment-knowledgeable =>50% reduced Sudden Step-3 Initial Maintenance Stds. Equipment-knowledgeable =>50% reduced Sudden Step-3 Initial Maintenance Stds. Equipment-knowledgeable =>50% reduced Sudden
operators. operators. operators. operators. breakdowns. breakdowns. breakdowns. breakdowns.
Step-4 General Inspection Skills General check-up of => 90% reduced SuddenStep-4 General Inspection Skills General check-up of => 90% reduced SuddenStep-4 General Inspection Skills General check-up of => 90% reduced SuddenStep-4 General Inspection Skills General check-up of => 90% reduced Sudden Training & Implement equipment by operators. breakdowns. Training & Implement equipment by operators. breakdowns. Training & Implement equipment by operators. breakdowns. Training & Implement equipment by operators. breakdowns.
Step-Step-Step-Step-5/5/5/5/6 Autonomous Inspection AM/Pl Maint. responsibility => 95% reduced Sudden6 Autonomous Inspection AM/Pl Maint. responsibility => 95% reduced Sudden6 Autonomous Inspection AM/Pl Maint. responsibility => 95% reduced Sudden6 Autonomous Inspection AM/Pl Maint. responsibility => 95% reduced Sudden optimized. breakdowns. optimized. breakdowns. optimized. breakdowns. optimized. breakdowns.
Step-7 Organize & manage Self Managing Work TBD.Step-7 Organize & manage Self Managing Work TBD.Step-7 Organize & manage Self Managing Work TBD.Step-7 Organize & manage Self Managing Work TBD. workplace. Teams. workplace. Teams. workplace. Teams. workplace. Teams.
9
Start at Start at Start at Start at AMAMAMAM0 - Baseline Status0 - Baseline Status0 - Baseline Status0 - Baseline Status�Prepared by Maintenance personnel.
� Systematize Defect and Breakdown knowledge in terms of the 5 Basic Machine Conditions (BMCs)
� TPM believes that zero breakdowns and zero defect can be achieved if the BMCs ( free of Contamination, correct lubrication, correct bolting, correct inspection and correct precision of machine functional parts) are strictly controlled.
� Provides a starting baseline from which Step AM1 Activities for Continous Improvement is launched.
AM0 F-Map To Help Find Fuguai PlanPlanPlanPlan forforforfor AM1AM1AM1AM1 CleaningCleaningCleaningCleaning &&&& InvestigationInvestigationInvestigationInvestigation MapMapMapMap (For AM2a,2b - Eliminate Contamination & Improve Accessibil ity)
Team:Team:Team:Team: LegacyLegacyLegacyLegacy TeamTeamTeamTeam
AssemblyAssemblyAssemblyAssembly #1:#1:#1:#1: InputInputInputInput LoaderLoaderLoaderLoader AssemblyAssemblyAssemblyAssembly BMCsBMCsBMCsBMCs extractedextractedextractedextracted fromfromfromfrom RCARCARCARCA BMCBMCBMCBMC GpGpGpGp ListListListList ofofofof FuguaiFuguaiFuguaiFuguai RestorationRestorationRestorationRestoration ofofofof FuguaiFuguaiFuguaiFuguai
CannotCannotCannotCannot loadloadloadload devicedevicedevicedevice intointointointo expansionexpansionexpansionexpansion tracktracktracktrack
BD1 BD1.BD1.BD1.BD1. CannotCannotCannotCannot loadloadloadload devicedevicedevicedevice intointointointo expansionexpansionexpansionexpansion track.track.track.track. 1a1 Loader stop pin damage. 3a FR None None1a2 Worn-out expansion track 3c FR None None1a3 Up/down reflective sensor loose connection. 1 FL None None1a4 Bolts not properly tight that hold up/down reflective sensor. BR None None1a5 Bolts not properly tight that hold flag loader position lock pin. BR None None
1a6 Worn-out loader pivot FR None None 1a7 Bolts not properly tight that hold insert loader pivot. BR None None
1a8 Bolts not properly tight that hold wheel singulator drive. BR None None
FuguaiFuguaiFuguaiFuguai discovereddiscovereddiscovereddiscovered duringduringduringduring FFFF----TaggingTaggingTaggingTagging BMCBMCBMCBMC GpGpGpGp1b11b11b11b1 Bolt 6-32 MissingMissingMissingMissing Completion1b21b21b21b2 Gasket DamageDamageDamageDamage Replaced1b31b31b31b3 Lock washer 6-32 MissingMissingMissingMissing Completion1b41b41b41b4 Insert loader pivot 2b NoneNoneNoneNone None1b51b51b51b5 bolts 6-32 loader pivot insert WrongWrongWrongWrong screwscrewscrewscrew Replaced1b61b61b61b6 Pin loader pivot 2a NoneNoneNoneNone None1b71b71b71b7 Loader base mounting 4b NoneNoneNoneNone None1b81b81b81b8 Loader base 4a NoneNoneNoneNone None1b91b91b91b9 Flag loader stop pin 3b NoneNoneNoneNone None
1b101b101b101b10 Loader pivot spring DamageDamageDamageDamage Replaced1b111b111b111b11 Miniature basic switch DamageDamageDamageDamage terminalterminalterminalterminal supplysupplysupplysupply Replaced1b121b121b121b12 Button loader pivot wornwornwornworn outoutoutout Replaced1b131b131b131b13 Spring clamp magazine wornwornwornworn outoutoutout Replaced
Total:Total:Total:Total: 8888 FuguaisFuguaisFuguaisFuguais
AssemblyAssemblyAssemblyAssembly #### 2222 :::: StorageStorageStorageStorage AssemblyAssemblyAssemblyAssembly BMCsBMCsBMCsBMCs extractedextractedextractedextracted fromfromfromfrom RCARCARCARCA BMCBMCBMCBMC GpGpGpGp ListListListList ofofofof FuguaiFuguaiFuguaiFuguai
3a
3c
2b
3b
4a
4b
2a
1
Left
Right
Right
Left
11
( Step-1 : Restoration & Investigation )( Step-1 : Restoration & Investigation )( Step-1 : Restoration & Investigation )( Step-1 : Restoration & Investigation )( Step-1 : Restoration & Investigation )( Step-1 : Restoration & Investigation )( Step-1 : Restoration & Investigation )( Step-1 : Restoration & Investigation )
OPERATORS
LEADER
MAINT.STAFF
ENGR.STAFF
CONFIRMATION OF PROGRESSDEPT.CHIEF
SUPERVISORSGROUP LEADER
LIST OF EXT/INTABNORMALITIES
MEETING TOPLAN COUNTERMEASURES
COUNTERMEASURES
STEP-1 AUDITMODEL MACHINE
MAINTENANCESTAFF
ENGINEERING STAFF
AUTONOMOUSMAINTENANCEGROUP
FOLLOW UP ON AUDITFEEDBACK
COUNTERMEASURESEXTENDED TO ALL
EQUIPMENTAUDIT
DEPT.CHIEF
LEADER
SUPERVISORS
TO NEXT STEP
Find Contam & Access SamplePlanPlanPlanPlan forforforfor AM1AM1AM1AM1 CleaningCleaningCleaningCleaning &&&& InvestigationInvestigationInvestigationInvestigation MapMapMapMap (For AM2a,2b - Eliminate Contamination & Improve Accessibility)
Team:Team:Team:Team: BaggingBaggingBaggingBagging Team.Team.Team.Team. Equipment:Equipment:Equipment:Equipment: BaggingBaggingBaggingBagging MCMCMCMC
AssemblyAssemblyAssemblyAssembly #1:#1:#1:#1: BagBagBagBag PickingPickingPickingPicking AssyAssyAssyAssy BMCsBMCsBMCsBMCs extractedextractedextractedextracted fromfromfromfrom RCARCARCARCA DescribeDescribeDescribeDescribe ContaminationContaminationContaminationContamination AccessibilityAccessibilityAccessibilityAccessibility problemsproblemsproblemsproblemsBD1.Bag Picking Assy cannot pick bag Contamination
to the roller printer. 1a3) Cleaning the air f ilter. BD#1a - Vac Cup Suction Low * No standing space to remove and
1a1) Suction cup w orn/harden replace f ilter.1a2) Suction tubes loose/broke1a3) Air f ilter clogged 1a3) Air f ilter clogged Other BMC Groups1a4) Pump impeller broke * Water f rom air suppy IA. 1a4) Pump impeller 1a5) Pump motor burned * Collected on f ilter elements * Inside assembly cannot see.
1a6) Pump bearing w orn * From Air Compressor. 1a5) Pump motor burned BD#1b - Vac Cup cannot reach Bags. * Affects a new f ilter performance * Inside assembly cannot see.
1b1) Cylinder leakage w ithin 2 w eeks. 1a6) Pump bearing w orn1b2) Solenoid valve jammed * Inside assembly cannot see.1b3) Air f ilter clogged 1b4) No w ater trap
HistoricalHistoricalHistoricalHistorical BMCsBMCsBMCsBMCs (not(not(not(not above)above)above)above)BoltsBoltsBoltsBolts (fuguai/contam/Access)(fuguai/contam/Access)(fuguai/contam/Access)(fuguai/contam/Access)LubrLubrLubrLubr (fuguai/contam/Access)(fuguai/contam/Access)(fuguai/contam/Access)(fuguai/contam/Access)
Future BD Areas to be investigated: BMCsBMCsBMCsBMCs fromfromfromfrom FuguaiFuguaiFuguaiFuguai FoundFoundFoundFound DescribeDescribeDescribeDescribe ContaminationContaminationContaminationContamination AccessibilityAccessibilityAccessibilityAccessibility problemsproblemsproblemsproblemsContamination
1) Remove covers of gear assembly Tag 1-FR : Belts w ere w orn and Tag 3-Contam: Dust over elect Tag 3-Contam: Dust over electhousing and do a clean/tag of the belts, have play. w ires and joints. w ires and joints.gears and electrical contacts. Tag 2-FR/Lubr : Gear Assy * dust f rom environment enter * Need to remove 8 screw s
movements noisy through vent gaps over time. to take out covers. rustand no lubricant.
Tag 3-Contam: Dust over electw ires and joints.
More Before & After Pictures
13
(Note: Need To Raise Maintenance Work Order For F-Tag Repairs)
AM1AM1AM1AM1 ProvisionalProvisionalProvisionalProvisional CleaningCleaningCleaningCleaning MonthlyMonthlyMonthlyMonthly CalendarCalendarCalendarCalendar
Machine name: REACTOR POL MP2 No of machine: 3 Month:
No. ID Code Assembly Cleaning Item Criteria Method Tool Date
Cleaning area ( Diagram)OneOneOneOne PerPerPerPer WeekWeekWeekWeek 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
1 1111 Floor Reactor Floor No chemical
spillage at floor Clean Mop OOOO OOOO OOOO OOOO OOOO
2 2222 Reactor Reactor Grease chute container
Grease level half of conainer level
Clean Scope OOOO OOOO OOOO OOOO OOOO
3 13131313 Floor Reactor Floor No waste material
at floor Clean Broom OOOO OOOO OOOO OOOO OOOO
4 14141414 Raw Material Feed Line IO-PT Line Bracket No loosen bracket Wiping Cutton rag OOOO OOOO OOOO OOOO OOOO
OneOneOneOne PerPerPerPer MonthMonthMonthMonth 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
5 3333 Hot Water Line hot water flexible hose No spash grease Clean Cutton rag OOOO
6 4444 N2 Line N2 Line to Reactor No rusy Wiping Cutton rag OOOO
7 5555 CHW LineCHW Line to Reactor
Jacket No rusty Wiping Cutton rag OOOO
8 6666 Raw Material Feed DO LineNo rusty and No
leaking Wiping Cutton rag OOOO
9 7777 Reactor Reactor gear housing No contamination stick at housing
Clean Brush and cutton rag OOOO
10 8888 ReactorReactor Vent Line
InsulationProper Heat
Insulation Clean Brush and cutton rag OOOO
11 9999 Reactor CW Line to Reactor No corrosive and
rusty Clean Brush and cutton rag OOOO
12 10101010 ReactorReactor Main Motor
Cooling Fan No hard scale Clean Brush , cotton rag OOOO
13 11111111 ReactorReactor Main Motor
Stand / Stack No rusty Clean Brush and paint OOOO
14 12121212 OthersMain Motor Belt Safety
Cover No rusty Clean Brush and paint OOOO
15 15151515 DO Rounding LineDO / CHW Line
Insulation Proper Installation Wiping Cutton rag OOOO
Before After Before After
15
( Step-2a : Eliminate Sources Of Contamination ) ( Step-2a : Eliminate Sources Of Contamination ) ( Step-2a : Eliminate Sources Of Contamination ) ( Step-2a : Eliminate Sources Of Contamination ) ( Step-2a : Eliminate Sources Of Contamination ) ( Step-2a : Eliminate Sources Of Contamination ) ( Step-2a : Eliminate Sources Of Contamination ) ( Step-2a : Eliminate Sources Of Contamination )
Complete Step-1Complete Step-1Complete Step-1Complete Step-1
Step-1 Summary results & findings
What ?What ?What ?What ?
Where ?Where ?Where ?Where ?
How How How How muchmuchmuchmuch
Why ?Why ?Why ?Why ?
AM Team=> 70%
Countermeasures
1st 1st 1st 1st Pre-Auditby TPM Dept.
Present Countermeasuresto TPM WC andimplementation
GM/Sponsors
Audit
Step-3Step-3Step-3Step-3
Own areaBuy - Off
5. AM2a Contamination Analysis Worksheet (3/5) 5. AM2a Contamination Analysis Worksheet (3/5) 5. AM2a Contamination Analysis Worksheet (3/5) 5. AM2a Contamination Analysis Worksheet (3/5) AM-2A CONTAMINATION ANALYSIS AM-2A CONTAMINATION ANALYSIS AM-2A CONTAMINATION ANALYSIS AM-2A CONTAMINATION ANALYSIS
MACHINE:MACHINE:MACHINE:MACHINE: ASM5500QUESTIONS ABOUT CONTAMINATION SOURCE QUESTIONS ABOUT CONTAMINATION SOURCE QUESTIONS ABOUT CONTAMINATION SOURCE QUESTIONS ABOUT CONTAMINATION SOURCE DURING INVESTIGATIONSDURING INVESTIGATIONSDURING INVESTIGATIONSDURING INVESTIGATIONS
ACTUAL FACTS COLLECTED ACTUAL FACTS COLLECTED ACTUAL FACTS COLLECTED ACTUAL FACTS COLLECTED SKETCH THE CONTAMINATION FALL-PATHSKETCH THE CONTAMINATION FALL-PATHSKETCH THE CONTAMINATION FALL-PATHSKETCH THE CONTAMINATION FALL-PATH
MACHINE SECTION:MACHINE SECTION:MACHINE SECTION:MACHINE SECTION: Waferhandler - Port1 1111 What is it?What is it?What is it?What is it? Broken silicon piecesBroken silicon piecesBroken silicon piecesBroken silicon pieces2222 Where is the source? Where is the source? Where is the source? Where is the source? Wafer protruding from Port1 Elevator cassette3333 How the contamination got there? (The Fall-Path)How the contamination got there? (The Fall-Path)How the contamination got there? (The Fall-Path)How the contamination got there? (The Fall-Path) Not fully inserted because cassette was not seated
properly then smashed against lid housing upon port initialise
CONTAMINATION TYPE:CONTAMINATION TYPE:CONTAMINATION TYPE:CONTAMINATION TYPE: Broken wafer 4444 Why is the contamination there?Why is the contamination there?Why is the contamination there?Why is the contamination there? Wafer not fully inserted5555 When it get there?When it get there?When it get there?When it get there? Upon impact with underside of lid housing
REFERENCE # :REFERENCE # :REFERENCE # :REFERENCE # : CONTAMINATION BASELINECONTAMINATION BASELINECONTAMINATION BASELINECONTAMINATION BASELINE BASELINE MEASUREMENTBASELINE MEASUREMENTBASELINE MEASUREMENTBASELINE MEASUREMENTa)a)a)a) HOW MUCH? ( volume, weight, count or an actual HOW MUCH? ( volume, weight, count or an actual HOW MUCH? ( volume, weight, count or an actual HOW MUCH? ( volume, weight, count or an actual
sample)sample)sample)sample)1 broken wafer on 5 areas indicated
CONTAMINATION EFFECT :CONTAMINATION EFFECT :CONTAMINATION EFFECT :CONTAMINATION EFFECT :b)b)b)b) HOW LONG? - (Record the time for the Qty of HOW LONG? - (Record the time for the Qty of HOW LONG? - (Record the time for the Qty of HOW LONG? - (Record the time for the Qty of
contamination to accumulate) contamination to accumulate) contamination to accumulate) contamination to accumulate) 6 Months
BreakdownBreakdownBreakdownBreakdownDefectDefectDefectDefectContaminate LubricationContaminate LubricationContaminate LubricationContaminate Lubrication
xxxx General Area contaminationGeneral Area contaminationGeneral Area contaminationGeneral Area contamination
7. JH AM2a Audit Standards & Results.7. JH AM2a Audit Standards & Results.7. JH AM2a Audit Standards & Results.7. JH AM2a Audit Standards & Results.AREAAREAAREAAREA ELEMENTSELEMENTSELEMENTSELEMENTS MAXMAXMAXMAX POORPOORPOORPOOR GOODGOODGOODGOOD EXCELLENTEXCELLENTEXCELLENTEXCELLENT PTSPTSPTSPTS COMMENTS FOR SCORE COMMENTS FOR SCORE COMMENTS FOR SCORE COMMENTS FOR SCORE
BELOW MAXIMUMBELOW MAXIMUMBELOW MAXIMUMBELOW MAXIMUM 1. Is the level of cleaning
inspection started in Step 1 maintained as a regular part of the activities?
10101010
Evidence of ineffective cleaning & inspection
0000----3333
Reasonable implementation but can do better
4444----7777
Excellent adherence and embedded as part of process
8888----10101010
10
2. Is there evidence of training and development of members (visual controls, equipment functions, and tools)?
15151515
Little evidence of skill enhancement
0000----5555
Majority are demonstrating significant skills
6666----10101010
High levels of skill evident in the nos. of OPL’s and training
11111111----15151515
15
SK
ILL
UP
GR
AD
ING
SK
ILL
UP
GR
AD
ING
SK
ILL
UP
GR
AD
ING
SK
ILL
UP
GR
AD
ING
3. Are all participating in activities (attendance list)? Is MA able to explain activities & m/c functions? Is Team Leader coordinating activities?
10101010
Low attendance (<80%) and skill development or coordination
0000----3333
Some activity but inadequate development and attendance at <80%
4444----7777
High levels of participation (>80%) and MA are able to explain
8888----10101010
10
4. Are sources of contamination summarized into a list, thoroughly analyzed and effective countermeasures implemented?
15151515
Some information but disorganized
0000----5555
Some activity but generally inadequate
6666----10101010
High levels of activity and progress
11111111----15151515
13
Need to add latest Breakdowns and chronic defects in the Gap Analysis to find more sources of Contamination.
EQ
UIP
ME
NT
STA
EQ
UIP
ME
NT
STA
EQ
UIP
ME
NT
STA
EQ
UIP
ME
NT
STAT
US
TUS
TUS
TUS
5. Are the losses caused by contamination quantified and counter-measures to reduce contamination by >70% effective?
15151515
A vague idea of losses, and not quantified
0000----5555
Some activity in place but improvement to reduce contamination is < 70%
6666----10101010
Very progressive, with clear goals and results are >70% reduction of contamination.
11111111----15151515
15
6. Have maintenance tasks been identified for transfer to operators? Is there a plan to upgrade skills?
5555
Few if any
0000----2222
Some activities are in place but no plans
3333----4444
Skill levels are clear and transfer plans in place
5555
5
IMP
RO
VE
ME
NT
IMP
RO
VE
ME
NT
IMP
RO
VE
ME
NT
IMP
RO
VE
ME
NT
SS S S 7. Are the majority of “efu” closed or planned for closure?
5555
Most “efu” are still pending
0000----2222
Clear progress made on “efu” elimination
3333----4444
Most “efu” are closed or with action plan
5555
5
POTENTIAL SCORE POTENTIAL SCORE POTENTIAL SCORE POTENTIAL SCORE 75757575 ACTUAL SCORE ACTUAL SCORE ACTUAL SCORE ACTUAL SCORE 73737373 Overall = Overall = Overall = Overall = 96.5%96.5%96.5%96.5%
AM2a Audit Standards (JIPM-Compliant) AM2a Audit Standards (JIPM-Compliant) AM2a Audit Standards (JIPM-Compliant) AM2a Audit Standards (JIPM-Compliant)
18
AMAMAMAM2a2a2a2a Benefit: Benefit: Benefit: Benefit:
� AM2a focus against the sources of contamination and achieves => 70% reduction of the contamination baseline.
� By reducing Contamination we reduce machine breakdowns and product defects and makes the machine and workplace cleaner.
19
( Step 2b : Improve Equip Accessibility To Maintain ).( Step 2b : Improve Equip Accessibility To Maintain ).( Step 2b : Improve Equip Accessibility To Maintain ).( Step 2b : Improve Equip Accessibility To Maintain ).
AM LeaderAM LeaderAM LeaderAM Leader Model m/c Model m/c Model m/c Model m/c
Passed Passed Passed Passed Step 2 Step 2 Step 2 Step 2
Areas difficult orAreas difficult orAreas difficult orAreas difficult orinaccessible for cleaninginaccessible for cleaninginaccessible for cleaninginaccessible for cleaningchecking & lubricatingchecking & lubricatingchecking & lubricatingchecking & lubricating
Inaccessible Inaccessible Inaccessible Inaccessible
No Place To No Place To No Place To No Place To Stand Stand Stand Stand
Wiring or piping Wiring or piping Wiring or piping Wiring or pipingobstructobstructobstructobstruct
Cannot see Cannot see Cannot see Cannot see easilyeasilyeasilyeasily
Time ConsumingTime ConsumingTime ConsumingTime Consumingto cleanto cleanto cleanto clean
Time ConsumingTime ConsumingTime ConsumingTime Consumingto cleanto cleanto cleanto clean
Product ManagerProduct ManagerProduct ManagerProduct Manager
Operator Leader/ OperatorsOperator Leader/ OperatorsOperator Leader/ OperatorsOperator Leader/ Operators
SupervisorSupervisorSupervisorSupervisor
Model MachineModel MachineModel MachineModel MachineGoes To Goes To Goes To Goes To
Step 4Step 4Step 4Step 4
Pre-AuditPre-AuditPre-AuditPre-Auditby TPM Deptby TPM Deptby TPM Deptby TPM Dept....
W/C W/C W/C W/CBuy OffBuy OffBuy OffBuy Off
GMGMGMGMAuditAuditAuditAudit
OwnOwnOwnOwnAreaAreaAreaArea
Buy OffBuy OffBuy OffBuy Off
20
AMAMAMAM2b2b2b2b Benefit: Benefit: Benefit: Benefit:� Many maintenance items are Time-consuming and/or Hard-to-Access for Cleaning, Lubrication, Bolting, Inspection and Precision Checks.
� AM2b reduces accessibility time by => 70% of the baseline time.
21
AM3 Benefit:AM3 Benefit:AM3 Benefit:AM3 Benefit:�Based on "total fuguai" data, revise & Improve and expand the PM Job-list
�Operators become all-present Eyes, Ears, Hands For the accessible Sub-set of updated PM Job-list for Cleaning, inspection & precision checks.
Model Machine
Current PM Job-list Items
Current Items that Need Revision of Stds
New items to be added to PM Job-list
Current PM Job-list items that are OK
NEW PM Job-list items (Total QTY)
AM3 final recommended list
FPP Bagging
36 items 16 44 20 80 items 49 items
NPP Extruder
22 items 4 51 18 73 items 19 items
PM Joblist PM Joblist PM Joblist PM Joblist (AM3 Status) Sample Only(AM3 Status) Sample Only(AM3 Status) Sample Only(AM3 Status) Sample Only
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Continuous Im provem ent W orksheet For Updating PM Standards Job-list Item sContinuous Im provem ent W orksheet For Updating PM Standards Job-list Item sContinuous Im provem ent W orksheet For Updating PM Standards Job-list Item sContinuous Im provem ent W orksheet For Updating PM Standards Job-list Item sToolset N ame: Toolset N ame: Toolset N ame: Toolset N ame:
B D #1 Tubes jamB D #1 Tubes jamB D #1 Tubes jamB D #1 Tubes jam M 70SW 11 u/s v Addblocked drive v v ReviseDegraded proxim ity switch v Add
battery valve u/s v Addrot.drive jam , v NCAM 2 C-measures access panel Add
W orn earth wire v AddBD #2 Tubes cant BD #2 Tubes cant BD #2 Tubes cant BD #2 Tubes cant shiftshiftshiftshift
rot.drive jam , v Addproxim ity switch worn v Addtube tower dirty v v Revisecylinder leak v Addsingulator fingers loose v Addtube stack height loosen v Add
Tubes are not moving one by one smoothly and some jammin g are occuring.
Tubes are not able to be shifted one by one smoothly to the Loader Gripper.
New Fuguai Observed during Tagging…New Fuguai Observed during Tagging…New Fuguai Observed during Tagging…New Fuguai Observed during Tagging… . . . .
1. Base Unit 1. Base Unit 1. Base Unit 1. Base Unit Loader. Loader. Loader. Loader. Assy 1-1) Loader Input stack
To hold the tubes of devices while waiting to be loaded into the machine
Assy 1-2 Loader Tube shifter
PM items PM items PM items PM items D ecision D ecision D ecision D ecision a) no change b) revise stds c) add to PM list
Information source Information source Information source Information source (BD/Def/Fuguai/) (BD/Def/Fuguai/) (BD/Def/Fuguai/) (BD/Def/Fuguai/)
2) PM 2) PM 2) PM 2) PM Job-listJob-listJob-listJob-list
System ID - System ID - System ID - System ID - Drive/Elect/Pnue/Hd
y/W ater………… ........
Assy Assy Assy Assy overall overall overall overall function function function function
Early W arning Signs Early W arning Signs Early W arning Signs Early W arning Signs (M C or Product)(M C or Product)(M C or Product)(M C or Product)
M aint Parts M aint Parts M aint Parts M aint Parts Repaired/ ReplacedRepaired/ ReplacedRepaired/ ReplacedRepaired/ Replaced
AM Operators becomes Maintenance DeptAM Operators becomes Maintenance DeptAM Operators becomes Maintenance DeptAM Operators becomes Maintenance Dept’’’’s extra s extra s extra s extra ““““ears, ears, ears, ears, eyes, hands, noseeyes, hands, noseeyes, hands, noseeyes, hands, nose”””” to detect early signs of MC trouble and to detect early signs of MC trouble and to detect early signs of MC trouble and to detect early signs of MC trouble and
thus helped to change Un-Planned Events into Planned thus helped to change Un-Planned Events into Planned thus helped to change Un-Planned Events into Planned thus helped to change Un-Planned Events into Planned Events (Planned Maintenance)Events (Planned Maintenance)Events (Planned Maintenance)Events (Planned Maintenance)
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AM4 Benefit:AM4 Benefit:AM4 Benefit:AM4 Benefit:� Further improve/expand the PM Joblist from successful OEE big losses projects.
� Operators' scope increased, some experienced operators can do line maintenance.
M-Q (Machine-Quality) Summary after solving "Thickness Fails" chronic defect.
Copper Brush, Flipper Spring and Brass Bar.
Plating Chemical
Dryer Heater Corner Spray and Rinsing Water
Dryer Blower
Part of MachinePart of MachinePart of MachinePart of Machine Plating ChemicalPlating ChemicalPlating ChemicalPlating Chemical FlipperFlipperFlipperFlipper B. Bar / C. BrushB. Bar / C. BrushB. Bar / C. BrushB. Bar / C. Brush Dryer HeaterDryer HeaterDryer HeaterDryer Heater
Measurement Chemical Content Tension Contact Pressure Hot Air Temperature
Std. Value MSA: 37.5% +/- 5% Upper <= 250 g Upper = 6 kg/cm Upper = 130 deg. CTIN: 37.5 g/l +/- 5 g/l Nominal = 120g Nominal = 5.5 kg/cm Nominal = 125 deg CAdditive: 2 g/l +/- 0.5 g/l Lower => 60g Lower = 5 kg/cm Lower => 120 deg C
Interval Daily Weekly Forthnightly Daily
Quality Defect Quality Defect Quality Defect Quality DefectThickness FailThickness FailThickness FailThickness Fail Thickness FailThickness FailThickness FailThickness Fail Thickness FailThickness FailThickness FailThickness Fail Thickness FailThickness FailThickness FailThickness Fail
Quality of M/c PartQuality of M/c PartQuality of M/c PartQuality of M/c Part
Circularity
Content ���� O O O
Deterioration
Smoothness
9999 10101010 11111111 12121212 13131313
11112222333344445555
66667777
8888 14141414
Checked by Prepared by Phenomenon Physical view (Logical reasoning)
PM Analysis Chart No 3/5 Illegible or partial marking occurs during the marking process at TM06.
The rubber pad does not transfer a ll the full characters from the stamp plate to the package surface resulting in Illegible Marking
Contributing Condition Investigation Result 4 M Correlation, First Item
Investigation Result4M Correlation,
Second Item Investigation/ Investigation Result If NG, Countermeasure Result
Investigation M easuring Method
Temporary Decision Criterion
Measure - ment Value
DecisionInvestigation/ Measuring
MethodTemporary
Decision CriterionMeasure -
ment ValueDecision
(3rd, 4th, 5th and 6th Items
Measuring Method
Temporary Decision Criterion
Measure - ment Value
Decision why NG?Restoration, Replace - ment, Improvement,
Remodeling
Measurement Value
Decision
3. INCOMPLETEOR INSUFFICIENTDEPTH OF 9 - 11 mils 7 mils NG 3.1 Deterioration 0.49 W - 0.46 W NG 0.50 W OKCHARACTERS of laser Engraver 0.52WON STAMP PLATES. beam power
SIDESIDESIDESIDE VIEWVIEWVIEWVIEW OFOFOFOF PLATEPLATEPLATEPLATE
SIDESIDESIDESIDE VIEWVIEWVIEWVIEW OFOFOFOF PLATEPLATEPLATEPLATE Laser after powerdeterioration
Actual Laser
Characters not beenengraved deeply caused illegible marking. Characters not been
engraved deeply caused illegible marking.
2. Uneven stamp Even layer No method NGplate layer. to measure
3. Residue ink on No ink residue Have ink NG 1. Not fully 1. To immerge 60 to 65 mm OKused plate. in characters residue immerged in Stamp Plate into 75 mm
or stamp plate acetone after use. acetone properly.2. Delayed to 2. Immediately maximum 15 min OKimmerge stamp immerge the plate 30 minin acetone. after use. after 3. Stamp plate usednot cleanedproperly.4. Acetone 4. To change the No No OKcontainer dirty. acetone 2x per week Illegible Illegible
marking. marking.
Design of Experiments During P-M Analysis For Design of Experiments During P-M Analysis For Design of Experiments During P-M Analysis For Design of Experiments During P-M Analysis For Chronic DefectsChronic DefectsChronic DefectsChronic Defects
OEE = Availability x Performance Rate x Quality Rate
OEE Waterfall Chart Single-Dimensional chart (Less Useful)
1. Speed Loss2. MTBA & Idling
OEE Loss Analysis ChartQuantity Vs Time 2-D Chart (More Useful)
Speed Loss(Company gap)
MTBA & Idling
Quality Loss
Speed Loss (World class gap)
Availability Loss
Source: JIPM 2014 Criteria.
frequently Process Improvements takes several months during which unpredictable changes
in energy, materials, overhead costs, new process problems. etc offset or hide the real cost reductions achieve by them causing possible loss of motivationVisit www.leantargetcosting for a software solution.
Using Costs To Drive C.I. Activities Software uses Toyota Principles, TPM OEE, Lean 6S.
Watch on Youtube, Youku, Vimeohttps://www.youtube.com/watch?v=A-YG7K-E-d0
Watch on Youtube, Youku , Vimeo https://www.youtube.com/watch?v=c-sqDNGmSGk&t=10s
Principles of measuring ROI of Lean 6S and TPM OEE Projects - 1min 45s
How to plan X% Product Cost Reduction & link to CI, TPM, Lean 6S - 2min 46s
Notes:1. The Process Yield Project can reduce the Process Cost by 9.21% (Rank 1 ticked)
Note: Red numbers are Cost-Reductions adjusted to Baseline conditions to eliminate noise.
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