tpm 02

Confirmation of result & relapse prevention

• Draw up Kaizen sheet and then confirm the result of loss reduction with comparison between before and after kaizen.• Revise Kaizen point of drawing, standard and working procedure• Draw up one point lessons about operator’s skill what was be clear through kaizen activity.• After kaizen activity, it needs to install visual control to necessary point.

Productivity Management Office @

Why – Why Analysis

• This is an analysis that repeat why about 4M root causes of problem several times. 4M (Machine, Material, Method, Man)

• First of all, investigate phenomenon and scene to find out cause of problem and then try to do why-why analysis.

• It is useful not only for production field but also different field.• The important point for analysis is to be clear what is problem.• Examine human cause at the end of analysis.


PM Analysis

phenomenonContributing conditionPhysical viewing

F3 is not zero

4M cause

Vacuum area is small

Vacuum power is small

F1 is small less than standard

Vacuum power is small less than falling power

Lift aim can not pick up tray

Gap of vacuum position

Tray is heavyF2 is heavy more than standard

Lifting power is small

Part 5 Consulting Experience sharing


Zero concept and model


Zero injuryZero pollution

• Zero model machine

• Zero model line

• Zero model area

Zero machine failure

Zero minor stops

Zero quality defect

Zero cleaning etc.

Relationship between AM and others

Autonomous maintenance 7steps

• Step 0 Preparation• Step1 Initial cleaning• Step2 Countermeasures for source of

contamination and hard to access.• Step3 Tentative CIL standard• Step4 General inspection• Step5 Autonomous inspection• Step6 Standardization• Step7 Autonomous management

Planed maintenance for Zero failurePlaned maintenance 7 Steps

Step1 Recognition of current maintenance systemStep2 Set up purpose, policy, target.Step3 Organization formation and clarification Step4 Clarification of implementation activitiesStep5 Study of specific implementation for each activity Step6 Plan farming for implementation with autonomous maintenanceStpep7 Result verification and establishment of maintenance system


Example of implementation activities

1. Support activity of Autonomous maintenance2. Zero failure activity3. Lubrication management activity4. Spare parts management activity5. Maintenance skill up and new technology activity6. Maintenance cost down activity7. Maintenance management system activity8. Maintenance project management activity

Visualize maintenance procedure


Kaizen scenario of sales growth

• Cooperation is significant between sales and manufacturing• Can make but can not sale, can sale but can not make• Which production system is better A or B?• Which product is better for kaizen A or B?

Sales

Sales P2

P1

a b

s

0 1 2 3 4


ContraryFor cost

ContraryFor profit

Opportunity loss

Volume

Opportunity loss

Kaizen scenario of cost down

• It should be improved difference of cost and aimed for Real standard cost.

• It should be considered ideal standard cost (long term) and real standard cost

(short term).

Actual cost


Standard cost

Present standard cost

Real standard cost

Ideal standard cost Level3 : Target cost in future

Level2n : Target cost after kaizen

Target1 : Target cost at present

= Actual cost – standard cost

Actual loss (difference of cost)

Loss analysis ( Loss tree )

• It makes clear loss structure and plan strategy.


Past loss

Forecast loss

Past Opportunityloss

Opportunityloss

Production costloss

Production losses

Production cost loss

IndirectProduction loss

Claim loss

Stock loss

SalesManagement loss

Past loss

Management of Kaizen theme

• Team leader manages individual kaizen theme and Focused improvement subcommittee manage whole themes by matrix as below.


Large theme Middle theme Small theme Initial Target Actual Parson Date of begin

Date of end Achievement

Theme 1

Theme1-1 Theme1-1-1

Theme1-1-2

Theme1-2

Theme1-2-1

Theme1-2-2

Theme1-2-3

Theme1-2-4

Theme1-3 Theme1-3-1

Theme1-3-2

Part 6 overall Program Summary


Key of success

1. Clear TPM policy of top management2. Alignment between Business plan and TPM plan3. Management of plan, target and results4. Priority themes and model activities5. Incentive for full participation6. Leadership of each level7. Budget for TPM activity.


Tangible result of TPM ( Example)

• P Value-added Productivity x1.5~Number of Unexpected break down 1/100~Overall equipment efficiency x1.5~

• Q Quality defect in process 1/10~• Customer claim ¼~• C Valuable cost down 30%~• D Inventory ½ ~• S Zero accident zero• Environmental pollution zero• M Turnover ½~

TPM Award

1) Award for TPM Excellence, Category BThe applicant must score a minimum of 70 points on 100-point Checklist C.2) Award for TPM excellence category AThe applicant must score minimum 70 points on 100 point checklist c3) Award for excellence in consistent TPM commitmentThe applicant must score minimum 80 points on 100 point checklist c4) Special award for TPM achievement The applicant must score minimum 70 points on 100 point checklist B5) Advanced special awards for TPM achievement The applicant must score minimum 80 points on 100 point checklist A6) Award for world class TPM achievement The applicant must score minimum 80 points on 100 point checklist S

1st Stage Assessment : May-July 201x 2nd Stage Assessment : October-December 201x+

• Checklist C exampleTPM policies and objectives1.

1. TPM policies are planned in relation between company policies and plant/factory policy2. The relation between TPM target values and management target results are clear

3. The master plan is in an appropriate order as an action plan to achieve TPM4. TPM policies and objectives are checked using method such as benchmarking that all sections of PQCDSME are

displayed corresponding to 8 pillars5. TPM policies and objectives are have been set forth and observed by all the departments

tpm 02

Education