Welcome to TPM Welcome To Elsmar com TPM

Welcome to TPM Welcome To Elsmar. com TPM Awareness Information 1

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. Elsmar. com TPM Awareness Information 2

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 Elsmar. com TPM Awareness Information 3

T. P. M. = Medical Science of Equipment PRODUCTION Foton AUTOMATION B-820 VIDEO-AUTO DIE-BONDER MODEL 8030 A POWER HEATER Elsmar. com TPM Awareness Information 4

The Main objective of TPM is : Zero Interruptions Zero Defects Zero 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 Elsmar. com TPM Awareness Information 5

PILLARS OF TPM A U T O N O M O U S M A I N T E N A N C E Q U A L I T Y M A I N T E N A N C E P L A N N E D M A I N T E N A N C E I N D I V I D U A L I M P R O V E M E N T T R AI NI N G P E O P L E D E V E L O P S A F E T Y E H S E A R L Y E Q U IP M A N A G E M E N T 5 S´s Elsmar. com TPM Awareness Information 6

T. P. M. Total Productive Manufacturing People , Equipment and Product Improvement by Working Together. EXCELLENCE Elsmar. com TPM Awareness Information 7

PLANT OVERVIEW Elsmar. com TPM Awareness Information 8

TPM Self Assessment PLANT OVERVIEW TPM Self Assessment Elsmar. com TPM Awareness Information 9

TPM Self Assessment Background: 1991 First attempt to implement TPM consultant provides training to selected Managers, Supervisors and Engineers. One coordinator with experience in Process and Maintenance is assigned to lead TPM. Literature and materials, prepared and distributed. Lack of support and involvement results in failing the implementation. Elsmar. com TPM Awareness Information 10

1996 TPM Self Assessment Continuing One Staff Mgr. is assigned to lead the TPM Implementation plant wide. A core team is formed on 2 Q/96 with key people from different departments 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. Elsmar. com TPM Awareness Information 11

Asia Benchmarking PLANT OVERVIEW TPM Self Assessment Asia Benchmarking Elsmar. com TPM Awareness Information 12

TPM Benchmarking Asia Facilities Facility 1 Facility 2 Facility 3 Committee: Objective: Elsmar. com 1996 April May June 4 Chosen Folks Learn from Asia success experiences in TPM implementation and come up with directions for Plant implementation. TPM Awareness Information 13

Benchmarking Conclusions Total management involvement. Elsmar. com 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. TPM Awareness Information 14

TPM Implementation PLANT OVERVIEW TPM Self Assessment Asia Benchmarking TPM Implementation Elsmar. com TPM Awareness Information 15

IMPLEMENTATION/CONSULTANT * Q 3 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 Elsmar. com TPM Awareness Information 16

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 THROUGHOUT SHOP FLOOR. ( Autonomous Maintenance, Planned Maintenance etc. . ) # ESTABLISH A RELIABILITY AND MAINTAINABILITY SYSTEM TO MAXIMIZE EQUIPMENT 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 SUPPORT T. P. M. GOALS. Elsmar. com TPM Awareness Information 17

T. P. M. PLANT WIDE STRUCTURE TPM Responsible Plant Manager T. P. M. Office 5 ´s Quality Maintenance Elsmar. com Autonomous Maintenance Early Equipment Management Planned Maintenance Safety TPM Awareness Information Individual Improvement Training People Development 18

PROMOTION STRUCTURE (OVERLAPPING SMALL GROUPS) PLANT MANAGER STAFF MANAGERS OPERATIONS TPM PILLARS & PROMOTION OFFICE DEPARTMENT MANAGERS DEPARTMENT SUPERVISORS TPM PROMOTERS TPM TEAM Elsmar. com TPM Awareness Information 19

VISION STATEMENT: TPM PLANT WIDE IMPLEMENTATION Q 1 2000 Elsmar. com TPM Awareness Information 20

T. P. M. IMPLEMENTATION ACTIVITIES MANAGER TEAMS Elsmar. com TPM Awareness Information 21

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. ) Elsmar. com TPM Awareness Information 22

Line and Machine Selection PRODUCTION Foton AUTOMATION B-820 VIDEO-AUTO DIE-BONDER MODEL 8030 A Machine 1 Machine 2 N-661 POWER HEATER Machine 3 Machine 4 B-609 V-701 Elsmar. com TPM Awareness Information 23

TPM Implementation Plan ACTIVITIES DEFINE STRATEGIES MASTER PLAN PREPARATION ORGANIZATION STAGE INTRODUCTION TRAINING PUBLICITY I M P L E M E N T A T I O N S T A R T T A R G E T MODEL MACHINES Machine 1 Machine 2 Machine 3 Machine 4 EXTEND IMPLEMENTATION SIMILAR PRODUCTION LINES COMPLETE IMPLEMENTATION DEFINED AREAS 1996 1997 1998 1999 Q 3 Q 4 Q 1 Q 2 1 T P M 2 2000 Q 3 Q 4 Q 1 Q 2 3 AUTONOMOUS MAINTENANCE K & I REDUCE 6 BIG LOSSES C K O F F EXTEND SIMILAR MACHINES 30% to 50% 100%

TPM 90 Days Explosion Plan October ww 40 ww 41 ww 42 November ww 43 ww 44 Machine 1 PILOT TEAM PILLARS Step 3 Planned maintenance 6 big losses Individual Improvement 10 Extension teams step 1 -2 19 Extension teams Start step 1 Machine 2 PILOT TEAM Step 2 -3 Planned maintenance 6 big losses Individual Improvement 11 Extension teams step 1 -2 Machine 3 PILOT TEAM Step 2 -3 Planned maintenance 6 big losses Individual Improvement 6 Extension teams step 1 -2 2 Extension teams Start step 1 Machine 4 PILOT TEAM Step 1 -2 Planned maintenance 6 big losses Individual Improvement 4 extension teams Start step 1 IMPLEMENTATION MODEL GANTT TPM Activity Board Extension Teams Server Data collection GM Audit Team presentations TPM Office Audit Consultant visit TPM Meeting Local BOOT CAMP TPM MCOE MEETING, JAPAN Pillars meeting ww 45 ww 46 December ww 47 ww 48 ww 49 ww 50 ww 51 ww 52 4 mc 7 mc 3 mc 6 mc Start Start Step 1 Step 2 B-613 3 mc Step 1 2 mc B-601 L-604 Start 2 mc 4 mc Start a-820 a-821 M 1 J-701 Start J-601 M 2 M 3 M 4

T. P. M. TRANSITION CURVE POLICIES DEVELOPMENT T. P. M. PROMOTION OFFICE START MANAGEMENT MACHINES FOCUS IN FEW EQUIPMENT FOCUS TRAINING SUCCESS STORIES 5 S´s D E N I A L KICK OFF CONSULTANT IN DEVELOP DATA COLLECTION SYSTEM ATTENTION TO FOCUS TEAMS TRAINING DEPLOYMENT IMPLEMENTATION PLAN RESOURCE IMPLEMENTATION Elsmar. com T. P. M. PROMOTION DELEGATION INCLUDE T. P. M. IN PERFORMANCE MANAGEMENT PLAN. INCLUDE T. P. M. IN JOB DESCRIPTION. ACCELERATED DEPLOYMENT. CONSULTANT OUT R E S I S T A N C E E X P L O R A T I O N C O M M I T M E N T GOALS SETTING FOR ALL ORGANIZATION. LOOK FOR ADDITIONAL WAYS TO DEPLOY T. P. M. FINISH CONFLICT WITH THE CULTURE ORGANIZATION ALIGNMENT REWARD SYSTEM CONTROL CHAOS TPM Awareness Information 26

KEY GOALS 1. - TOTAL EQUIPMENT EFFECTIVENESS A) Equipment Breakdown B) M. T. B. A. C) M. T. B. F. % HOURS/MONTH MINUTES HOURS 85 1/10 1 x 10 x 1 x 2 x 2. - REJECT CAUSED BY LINE EQUIPMENT PPM 1/5 % 1/5 3. - LINE REJECT RATE 4. - CYCLE TIME DAYS 0. 8 X 5. - FATAL ERROR AT CUSTOMER # OF 0 6. - ON TIME DELIVERED % 7. - MANUFACTURING COST USD 8. - LABOR PRODUCTIVITY K. UNITS /# OF D/L Elsmar. com TPM Awareness Information 98 20% LESS 2 X 27

AUTONOMOUS MAINTENANCE. MANUFACTURING SPECIALIST Elsmar. com TPM Awareness Information 28

AUTONOMOUS MAINTENANCE IS: Maintenance performed by equipment operators. THE FIRST 3 STEPS OF AUTONOMOUS MAINTENANCE. STEP # 1 INITIAL CLEANING. STEP # 2 COUNTERMEASURES FOR THE CAUSES OF FORCED DETERIORATION AND IMPROVING HARD-TO-ACCESS AREAS. STEP # 3 MAKING A TENTATIVE CLEANING/ LUBRICATION STANDARD. Elsmar. com TPM Awareness Information 29

AUTONOMOUS MAINTENANCE 5 Formats: 6 Daily Cleaning & Initial Inspection 4 Hot Spots, CAP-DO 5 W´s Develop One Point lesson Major Problems Selection Step # 1 3 Put F Tags Initial Cleaning 7 Training in One Point Lesson Initial Cleaning (Inspection) 2 Standardization Cleaning / Lubrication 8 Photos Before Photos After 1 Elsmar. com TPM Awareness Information 30

AUTONOMOUS MAINTENANCE 5 Failures Analysis Why´s Analysis 4 6 Actions in Sources of Contamination & Hard access areas Put “F” Tags Step # 2 3 Find & List Areas of Hard Access Sources of Contamination & Hard Access Areas Find & List Sources of Contamination 2 Modify Covers For Easy Visualization & Quick Disassemble 7 Remove “F” Tags Initial Inspection Final Inspection (Audit) 8 1 Elsmar. com TPM Awareness Information 31

AUTONOMOUS MAINTENANCE 5 4 Improve time of execution Verify actual time Vs estimated 3 Put “F” Tags (Establish time & frequency) 3 2 Detail activities Step # 3 Tentative Standards Cleaning / Lubrication implementation 2 6 Remove “F” Tags 7 Apply activities to similar machines Develop tentative standards 8 1 Elsmar. com TPM Awareness Information 32

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: Elsmar. com TPM Awareness Information 284 126 44 34 27 1 2 24 33

Expansion Plan PLANT OVERVIEW TPM Self Assessment Asia Benchmarking TPM Implementation Expansion Plan Elsmar. com TPM Awareness Information 34

T. P. M. DEPLOYMENT L I N E F L O W CURRENT EQUIPMENT IN T. P. M. SAME KIND OF EQUIPMENT 1 9 9 8 1997 1999/2000 EXPANSION Elsmar. com TPM Awareness Information 35

PROJECTED PROGRESS IN TEAMS Line Wafer Process Line 1 Q-1’ 98 A. M. STEP # 1 A. M. STEP # 2 A. M. STEP # 3 11 16 03 Line 2 03 11 01 Line 3 03 08 01 Line 4 04 01 01 Elsmar. com TPM Awareness Information 36

T. P. M. FOLLOW-UP Elsmar. com TEAMS PRESENTATION TEAMS AUDITS 6 TEAMS PER MONTH TEAMS MEETING WEEKLY TPM Awareness Information Consultant X MANAGERS VISITS PRESENTATION TWO DAY EVERY TWO MONTHS MONTHLY MEETING 37

PLANT OVERVIEW Pilot Team Case Study TPM Self Assessment Asia Benchmarking TPM Implementation Expansion Plan Pilot Team Case Study Elsmar. com TPM Awareness Information 38

PILOT MACHINE N-62361 Elsmar. com TPM Awareness Information 39

Defectives 30 25 23 23 22 20 20 21 18 19 17 15 10 7 5 5 9 8 6 5 8 6 6 3 4 3 3 6 4 7 5 6 4 2 0 N-662361 JAN 96 JUN Elsmar. com FEB JUL N-61162 MAR AUG N-634766 APR SEP TPM Awareness Information MAY OCT 96 40

DOWN TIME N-662361 N-663242 N-649666 Elsmar. com TPM Awareness Information 41

CLEANING IS INSPECTION. . 5’S AUTONOMOUS MAINTENANCE Elsmar. com TPM Awareness Information 42

INSPECTION IS DETECTION. CRASH Broken Part Elsmar. com TPM Awareness Information 43

PRESSURE CORRECT INCORRECT TO MUCH PRESSURE CORRECT ALIGNMENT INCORRECT GAUGE Elsmar. com TPM Awareness Information NO 44

CORRECT CENTERING INCORRECT Dummy Part CORRECT SYMMETRY INCORRECT BENT Elsmar. com TPM Awareness Information 45

CONTACT CORRECT Elsmar. com TPM Awareness Information INCORRECT 46

TO STANDARDIZE AND PREVENT RECURRENCE One Point Lesson Elsmar. com TPM Awareness Information 47

MACHINE PERFORMANCE Elsmar. com TPM Awareness Information 48

Defectives “ZERO” Defectives DOWN TIME Elsmar. com TPM Awareness Information P. C. BOARD DAMAGED 49

WHAT IS NEXT? 6 Big Losses LINK 4 Autonomous Maintenance Elsmar. com TPM Awareness Information 3 4 Planned Maintenance 50

Elsmar. com TPM Awareness Information 51