TPMTPM

1. TPM – basic idea

2. Organisational structure of the TPM project

3. Presentation of the project and 6 sub-projects

4. TPM in Kolektor – results and goals

5. Questions and suggestions

DEVELOPMENT OF MAINTENANCEDEVELOPMENT OF MAINTENANCE

� BREAKDOWN MAINTENANCE

� PREVENTIVE MAINTENANCE (PM - 1951)

� CORRECTIVE MAINTENANCE (CM – 1957)

� MAINTENANCE PREVENTION (MP – 1960)

� PRODUCTIVE MAINTENANCE (PM + CM + MP)

� TOTAL PRODUCTIVE MAINTENANCE (TPM® – 1971)

Total in TPM means :

total effectiveness

total maintenance and

total paricipation of all employees

DEFINITION AND DISTINCTIVE DEFINITION AND DISTINCTIVE FEATURES OF TPMFEATURES OF TPM

� TPM aims to maximize equipment effectiveness

� TPM establishes a thorough system of PM for the equipments entire life span

� TPM is implemented by various departments(engineering, operations, maintenance)

� TPM involves every single employee, from top management to workers on the floor

� TPM is based on promotion of PM through

motivation management: autonomous small groups activities (TED in Kolektor)

OVERALL EQUIPMENT

EFFECTIVENESS

5S

AUTONOMOUS MAINTENANCE

QUICK CHANGEOVER-

SMED

IMPROVEMENT SUGGESTIONS

PREVENTIVE MAINTENACE

VlekIgor Bonč inaDejan Čadež

Divizija AMartin Kolenc

Uroš Felc

Stojan PetričPredsednik družbe

Radovan BolkoPodpredsednik družbe

Sebastjan FranziniVodja projekta

5SVodja: Andrej ViherDiv. A: Simon PavšičDiv. B: Andrej ViherDiv. C: Zdenko OgričDiv. D: Zdravko PelhanVlek: Dejan ČadežOrod..: Sebastjan FranziniASCOM: Nina Vest (nam.)Vzdrževanje: Aleksander Rutar

SAMOVZDRŽEVANJEVodja: Janez GostišaDiv. A: Simon PavšičDiv. B: Jure Benč ina (nam.)Div. C: Zdenko OgričDiv. D: Zdravko PelhanVlek: Dejan ČadežOrod..: Sebastjan FranziniASCOM: Bojan Hvala

MALE IZBOLJŠAVEVodja: Sebastjan FranziniDiv. A: Ivan KofolDiv. B: Veronika HitiDiv. C: Dejan Velikanje (nam.)Div. D: Boris JezeršekVlek: Igor BončinaOrod..: Sebastjan FranziniASCOM: Tatjana Carl

HITRA MENJAVA ORODIJVodja: Andrej BrložnikDiv. A: Uroš FelcDiv. B: Andrej BrložnikDiv. C: Janez Gostiša (nam.)Div. D: Zdravko PelhanVlek: Dejan ČadežOrod..: Sebastjan FranziniASCOM: Boris Carli

PREVENTIVNOVZDRŽEVANJEVodja: Ivo LogarDiv. A: D. Krapež, E. NamarDiv. B: I. Gnezda, M. MiheljDiv. C: P. Poljanec, B. FilipičDiv. D: P. Poljanec, B. FilipičVlek: M. Bratuž, T. ŠtravsOrod..: P. Poljanec, B. FilipičASCOM: M. Bratuž, T. Štravs

Divizija BSilvo Jesenko

Andrej Brložnik

Divizija CStanislav JerebJanez Gostiša

Divizija DValter LebanAleš Gostiša

OrodjarnaMiloš Kermavnar

Sebastjan Franzini

VzdrževanjeMarjan BrusIvo Logar

ASCOMBojan SeverNina Vest

ORGANIZACIJSKA STRUKTURA PROJEKTA TPM

UČINKOVITOST OPREMEVodja: Robert KosDiv. A: Robert KosDiv. B: Andrej Brložnik (nam.)Div. C: Dejan VelikanjeDiv. D: Aleš GostišaVlek: Igor BončinaOrod..: Sebastjan FranziniASCOM: Dimitrij Bevk

OVERALL EQUIPMENT EFFECTIVENESS

OEE = Availability x Performance x Qualityrate rate

BreakdownsSetupAdjustment

IdlingMinor stoppagesReduced speed

Defects and reworkStartup loss

Two types of equipment effectiveness in Kolektor:

OEE – calculated with all stillstandsPEE – exclude stillstands caused by poor

organization

OVERALL EQUIPMENT EFFECTIVENESSOVERALL EQUIPMENT EFFECTIVENESSOVERALL EQUIPMENT EFFECTIVENESSOVERALL EQUIPMENT EFFECTIVENESS

OVERALL EQUIPMENT EFFECTIVENESS

In all calculations we consider all stilstands, regardless of the reason:

Availability:

Net available time = Working days x Shifts x Planned no. of hrs/shift + exceptions

time available Net

time sstillstand All- time available Net=R

Performance effectiveness: time stilstands All- time available Net

run parts Totalx time cycle Ideal=Z

Quality rate: run parts Total

run parts Good=K

Overall equipment effectiveness:

SU = R x Z x KSU = R x Z x KSU = R x Z x KSU = R x Z x K

STILLSTANDS – TYPES AND DIVISION

Stillstands caused by equipmentStillstands caused by equipmentStillstands caused by equipmentStillstands caused by equipment

03 Tool missing

10 Machine breakdown

11 Tool breakdown

12 Set-up of machine/tool Bigger set-ups, change of tool, change of programme…

15 In-process set-up Shorter stillstands due to adjustments, …

23 Working place not in order Zastoji zaradi nepopolne urejenosti delovnega mesta (npr. – stroj naj bi delal avtomatsko, pa še ni avtomatiziran; ni zabojev; ni palet; ni VF generatorja…)

29 Autonomous maintenance Cleaning, lubricating, tightening, checking…

30 Technological problems

91 Poor quality The stillstand must have an according note of poor Q

Other stillstands Other stillstands Other stillstands Other stillstands (independent on equipment) – organisational stillstands 01 No work No work because there are no job-orders for the machine

02 No raw material

04 No energy

05 No set-up man

14 No material – semi-product

98 No worker

PSU = PR x Z x KPSU = PR x Z x KPSU = PR x Z x KPSU = PR x Z x K

PRODUCTION EQUIPMENT EFFECTIVENESS

When calculating production availability we consider only the stillstands caused by equipment. It tells us, how much of the planned time, the machine is capable of operating and there are no stillstands caused by poor organization.

Production availability: time sstillstand onalOrganisati - time available Net

time sstillstand All- time available Net=PR

Production equipment effectiveness: • Theoretical equipment effectiveness is calculated regarding to maximum available time

(callendar days x 24 hrs).

OEE (SU) AND PEE (PSU) IN KOLEKTOR OEE (SU) AND PEE (PSU) IN KOLEKTOR JANUARY JANUARY –– MARCH 2003MARCH 2003

Exploatation rate (I)

Production availability

(PR)Availability

(R)Performance

(Z)Quality

(K)

Overall equipment

effectiveness (SU=R*Z*K)

Production equipment

effectiveness (PSU=PR*Z*K)

Theoretical equipment

effectiveness (SUt)

DIVIZIJA A 0,885 0,890 0,875 0,871 0,996 0,759 0,771 0,604DIVIZIJA B 0,717 0,862 0,706 0,854 0,997 0,601 0,734 0,411DIVIZIJA C 0,676 0,885 0,649 0,834 0,997 0,539 0,736 0,301DIVIZIJA D 0,702 0,848 0,689 0,810 0,998 0,557 0,686 0,355PROKOL 0,818 0,868 0,801 0,914 0,998 0,730 0,791 0,523VLEK 0,736 0,789 0,722 0,747 1,000 0,540 0,589 0,288

KOLEKTOR 0,745 0,870 0,730 0,844 0,996 0,614 0,732 0,402

Overall equipment effectiveness

0,000

0,100

0,200

0,300

0,400

0,500

0,600

0,700

0,800

DIVIZIJA A -skupaj

DIVIZIJA B -skupaj

DIVIZIJA C -skupaj

DIVIZIJA D -skupaj

PROKOL -skupaj

VLEK - skupaj KOLEKTOR -skupaj

II kvartal 2002

III. Kvartal 2002

IV. Kvartal 2002

I. Kvartal 2003

Production equipment effectiveness

0,000

0,100

0,200

0,300

0,400

0,500

0,600

0,700

0,800

0,900

DIVIZIJA A -skupaj

DIVIZIJA B -skupaj

DIVIZIJA C -skupaj

DIVIZIJA D -skupaj

PROKOL - skupaj VLEK - skupaj KOLEKTOR -skupaj

II kvartal 2002

III. Kvartal 2002

IV. Kvartal 2002

I. Kvartal 2003

AUTONOMOUS MAINTENANCEAUTONOMOUS MAINTENANCE

� Autonomous maintenance refers to activities designed to involve operators in maintaining their own equipment, independent of the maintenance department

� It’s based on education and training of the operators

AUTONOMOUS MAINTENANCEAUTONOMOUS MAINTENANCE

� Daily checks

� Lubricating

� Parts replacement

� Simple repairs

� Precision checks

� Abnormality detection

We’ll clean every nook and cranny

Anything we can fix right away, we

will

Anything wrong here?

STANDARD SAMOVZDRŽEVANJA Stroj: STROJ RAZŽAGOVALNI AVT. TIP:RŽA 52/L-99 TED: Obrat: DIVIZIJA A

Št. stroja: 40495 Št. OS: 11621 Pogostost

Shema: Št. Opis Kriterij Metoda

Orodje/ mazivo I D T M

Odgovorni

1

Čiščenje stroja Površine stroja čiste Ročno Krpa, čistilo, metla, omelo

X Urejevalec

2 Kontrola nastavitve vpenjanja Pravilna nastavitev Test X

Urejevalec

3 Sesanje špen iz stroja Čist stroj Ročno Sesalec za špene

X Urejevalec

4 Mazanje ležajev ojnice Ležaji namazani Ročno Ročna mazalka/ Mast 90

X Urejevalec

5 Kontrola ožičenja

El. kabli ne smejo biti poškodovani, obrabljeni ali dotrajani, ne smejo prosto viseti po stroju

Vizualno X Urejevalec

6 Kontrola tesnjenja pnevmatike Brez puščanja Vizualno Slušno

X Urejevalec

7 Kontrola delovanja varnostnih sistemov (stikal)

Stroj ne deluje če: - zaščitno stikalo ni aktivirano

- je nujni stop vklopljen

Aktiviranje ali izklop varnostnih sistemov

X Urejevalec

8 Kontrola nastavitve optičnih in induktivnih senzorjev

Senzorji brez fizičnega kontakta

Vizualno X Urejevalec

Opombe: V primeru ugotovitve odstopanja, ki ga sami ne morete odpraviti, obvestite službo vzdrževanja.

Izdano dne: Odobril:

4

7

6

2

AUTONOMOUS MAINTENANCE IN AUTONOMOUS MAINTENANCE IN KOLEKTORKOLEKTOR

Development of Autonomous maintenance plans:

Number of machines

Standards made

Standards to be made

Conclusion plan

DIVIZIJA B 297 277 20 15.04.03DIVIZIJA A 354 41 313 15.06.03PROKOL 60 0 60 30.06.03DIVIZIJA C 215 40 175 31.07.03ORODJARNA 79 19 60 31.08.03VLEK 25 1 24 15.09.03ASCOM 253 6 247 31.11.03DIVIZIJA D 21 21 0 ConcludedSKUPAJ 1304 405 899 31.12.03

LEKCIJA Z ENO TEMO

Številka PREŠANJE 02

Tem

a

KONTROLA NASTAVITVE FOTOCELIC Datum izdelave

27.02.2002

Vodja oddelka Izdelal

Kla

sifi

kaci

ja

Osnovno Področje Problematično znanje izboljšav področje L. Gnezda,

R. Blaznik D. Brložnik

Datum

Predstavil

Slušatelji

Obr./1-1/386

Za kontrolo (nastavitev) fotocelic pritisni

tipko . Utripati prične rdeča lučka.

Na nasprotni strani mora žarek padati v

sredino belega kroga s križcem ali satjem. Kontrolo ponoviti na zgornji in spodnji strani. V primeru neustrezne nastavitve pravilno lego fotocelic nastaviti z ustreznim premikom nosilca fotocelic.

Single point lessons are a useful instrument for simple explanation and presentationof individual jobs, measures, improvements ... Especially in the field of autonomous maintenance

How How to to measure the effectiveness measure the effectiveness of TPM of TPM implementationimplementation??

� OEE and PEE� Time spent on corrective maintenance� Time spent on preventive maintenance� Total maintenance time� MTBF (mean time between failures)� MTTR (mean time to repair)� Stillstands time� Stillstands structure� Scrap� Number of improvement suggestions

Workplace before TPM

Workplace after TPM