LEAN Principles Total Productive Maintenance TPM Operational Equipment

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LEAN Principles Total Productive Maintenance (TPM) Operational Equipment Effectiveness (OEE) ECIC Consulting Inc. All

LEAN Principles Total Productive Maintenance (TPM) Operational Equipment Effectiveness (OEE) ECIC Consulting Inc. All rights reserved. 1

Goal of LEAN Making your shop more efficient By making equipment run more often

Goal of LEAN Making your shop more efficient By making equipment run more often not just faster. You can make more product by making better use of your time than you can by making things go faster. It’s the Tortoise vs the Hare. ECIC Consulting Inc. All rights reserved. 2

Todays Shop Challenges • Labor is getting harder to find and more expensive. •

Todays Shop Challenges • Labor is getting harder to find and more expensive. • Training good people is time consuming. • New Equipment is expensive. • Floor space is precious and short in supply. We all need to utilize what we have better vs getting more machines and hiring more people to run it. ECIC Consulting Inc. All rights reserved. 3

Session 1: Overview of TPM ECIC Consulting Inc. All rights reserved. 4

Session 1: Overview of TPM ECIC Consulting Inc. All rights reserved. 4

Overview of TPM What is TPM? Total Productive Maintenance (TPM) is a method to

Overview of TPM What is TPM? Total Productive Maintenance (TPM) is a method to achieve maximum equipment effectiveness through employee involvement Management + Operators + Maintenance ECIC Consulting Inc. All rights reserved. 5

Overview of TPM Machine failures have many hidden causes Failures are more Failure is

Overview of TPM Machine failures have many hidden causes Failures are more Failure is what we see but is only the tip of the iceberg expensive than maintenance Visible $$$$$$Failure$$$$$ Contamination Minor machine defects are generally unnoticed but are the cause of almost all machine failures Wear Loosening Leaks Corrosion Deformation Cracks Flaws Less Visible Vibration Improper Temperature Backlash ECIC Consulting Inc. All rights reserved. 6

Overview of TPM Failures Mean $$$ • Lost productive time $$$ • Production of

Overview of TPM Failures Mean $$$ • Lost productive time $$$ • Production of defects $$$ • Leads to shortages down stream in the manufacturing process. $$$ • Employee expense from inflicted downtime. • Late delivery or overtime costs $$$ ECIC Consulting Inc. All rights reserved. 7

Overview of TPM is a Paradigm Shift Operator I use Maintenance I maintain &

Overview of TPM is a Paradigm Shift Operator I use Maintenance I maintain & I fix Old Attitude Operator Maintenance We maintain TPM Attitude ECIC Consulting Inc. All rights reserved. 8

Overview of TPM Approach • Preventing breakdowns • Modifying equipment to prevent breakdowns and

Overview of TPM Approach • Preventing breakdowns • Modifying equipment to prevent breakdowns and make maintenance easier and faster. • Being prepared for common equipment failures. • Have the parts on hand the skills to make repairs as needed. ECIC Consulting Inc. All rights reserved. 9

Key TPM Tools Small Group Activities: Problemsolving Process Define the Problem A Collect Data

Key TPM Tools Small Group Activities: Problemsolving Process Define the Problem A Collect Data B C D E F Identify the Root Causes Implement Countermeasures Evaluate & Follow Up ECIC Consulting Inc. All rights reserved. 10

Make it run more not faster Equipment Loss Analysis & OEE ECIC Consulting Inc.

Make it run more not faster Equipment Loss Analysis & OEE ECIC Consulting Inc. All rights reserved. 11

Equipment Loss Analysis & OEE Introduction to OEE • OEE (Overall Equipment Effectiveness) is

Equipment Loss Analysis & OEE Introduction to OEE • OEE (Overall Equipment Effectiveness) is a metric that identifies the percentage of planned production time that is truly productive • How to understand OEE score? § An OEE score of 100% is perfect production § An OEE score of 85% is world class for discrete manufacturers § An OEE score of 60% is fairly typical for discrete manufacturers § An OEE score of 40% or less is not uncommon for manufacturers without TPM and/or lean programs What is your organization’s OEE score? ECIC Consulting Inc. All rights reserved. 12

Typical OEE Measurement Availability X Performance X Quality ECIC Consulting Inc. All rights reserved.

Typical OEE Measurement Availability X Performance X Quality ECIC Consulting Inc. All rights reserved. 13

Typical OEE Measurement • ECIC Consulting Inc. All rights reserved. 14

Typical OEE Measurement • ECIC Consulting Inc. All rights reserved. 14

Typical OEE Measurement • This is where the most losses are found. Changeovers and

Typical OEE Measurement • This is where the most losses are found. Changeovers and idle times between cycles of making a part etc…. ECIC Consulting Inc. All rights reserved. 15

Typical OEE Measurement • ECIC Consulting Inc. All rights reserved. 16

Typical OEE Measurement • ECIC Consulting Inc. All rights reserved. 16

Typical OEE Measurement • Availability X Performance X Quality ECIC Consulting Inc. All rights

Typical OEE Measurement • Availability X Performance X Quality ECIC Consulting Inc. All rights reserved. 17

Typical OEE Measurement • Improve machine effectiveness by reducing idle times Previous Example Model

Typical OEE Measurement • Improve machine effectiveness by reducing idle times Previous Example Model 33% One station can now make 2 X as many parts per day in the same 8 -hour day ECIC Consulting Inc. All rights reserved. 18

Equipment Loss Analysis & OEE Improvement Goals for the 6 Big Losses Type of

Equipment Loss Analysis & OEE Improvement Goals for the 6 Big Losses Type of Loss Goal Explanation 1. Breakdowns 0 2. Setups and adjustments minimize As short as possible; less than 10 mins with zero adjustments 3. Reduced speed 0 Should match or – with improvements – exceed equipment specifications 4. Minor stoppages 0 Should be zero for all equipment 5. Defects and rework 0 Extent may vary, but goal should be expressed in parts per million (ppm) 6. Startup loss Should be zero for all equipment minimize Source: TPM for Every Operator, Productivity Press Development Team ECIC Consulting Inc. All rights reserved. 19

Availability Setup & Adjustment Losses • Caused by changes in operating conditions, e. g.

Availability Setup & Adjustment Losses • Caused by changes in operating conditions, e. g. beginning of production runs or start-up at each shift, changes in products and conditions of operation • These losses consist of setup (equipment changeovers, exchanges of dies, jig and tools), start-up, and adjustment • Magnitude is measured in downtime ECIC Consulting Inc. All rights reserved. 20

Performance Minor Stoppage Losses • Caused by events such as machine halting, jamming, idling,

Performance Minor Stoppage Losses • Caused by events such as machine halting, jamming, idling, misfeeds, blocked sensors, etc. • Generally, these losses cannot be recorded automatically without suitable instruments • Formula: Losses = 100% - Performance Rate • Many companies regard such minor stoppages as breakdowns in order to emphasize their importance, even though no damage has occurred to the equipment ECIC Consulting Inc. All rights reserved. 21

Quality Defect & Rework Losses • Caused by off-specification or defective products § Rework

Quality Defect & Rework Losses • Caused by off-specification or defective products § Rework § Scrap • Losses consist of labor required to rework the products and the cost of the material to be scrapped • Measured by the ratio of quality products to total production • Sometimes designated as “quality defects in process” in order to distinguish from defective products during startup and adjustment operations ECIC Consulting Inc. All rights reserved. 22

Quality Start-up (Yield) Losses • Caused by unused or wasted raw materials • Exemplified

Quality Start-up (Yield) Losses • Caused by unused or wasted raw materials • Exemplified by quantity of rejects, scraps, chips, etc. • Yield losses are divided into two groups § Raw material losses resulting from product designs, manufacturing methods and equipment restrictions § Adjustment losses resulting from quality defects associated with commencement of work, changeover, etc. Includes setup and adjustment losses plus yield losses, in terms of both time and material losses ECIC Consulting Inc. All rights reserved. 23

Equipment Loss Analysis & OEE Strategies for Zero Breakdowns • Restore equipment • Maintain

Equipment Loss Analysis & OEE Strategies for Zero Breakdowns • Restore equipment • Maintain basic equipment conditions • Adhere to standard operating procedures • Improve operator maintenance skills • Don’t stop at quick fixes • Correct design weaknesses • Study breakdowns relentlessly ECIC Consulting Inc. All rights reserved. 24

CONTACT INFORMATION: Eric Ciampoli President ECIC Consulting Inc. Cell: 917 -703 -6079 eric@ecicconsulting. com

CONTACT INFORMATION: Eric Ciampoli President ECIC Consulting Inc. Cell: 917 -703 -6079 eric@ecicconsulting. com www. ecicconsulting. com ECIC Consulting Inc. All rights reserved. 25

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