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Courtesy, in part, of Motorola SPS. Thank You! Welcome To Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 1
Courtesy, in part, of Motorola SPS. Thank You! 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. Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 2
Courtesy, in part, of Motorola SPS. Thank You! 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 Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 3
Courtesy, in part, of Motorola SPS. Thank You! T.P.M. = Medical Science of Equipment PRODUCTION Foton AUTOMATION B-820 VIDEO-AUTO DIE-BONDER MODEL 8030A POWER HEATER Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 4
Courtesy, in part, of Motorola SPS. Thank You! 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 Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 5
Courtesy, in part, of Motorola SPS. Thank You! PILLARS OF TPM I P A M M M S E I M E M U A A A T A A N P O A T I I P I R F R Q D R P N O N N L N A E L U I O L A N T T A T I T Y A V V E G O E E E N Y L N I D E E E M N I N N N D I E M M Q O A T A E A U N V E E E U U N Y N D N A G E N N H I S C C C L L T T S P E E E O P 5S´s Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 6
Courtesy, in part, of Motorola SPS. Thank You! T.P.M. Total Productive Manufacturing People , Equipment and Product Improvement by Working Together. EXCELLENCE Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 7
Courtesy, in part, of Motorola SPS. Thank You! PLANT OVERVIEW PLANT OVERVIEW Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 8
Courtesy, in part, of Motorola SPS. Thank You! TPM Self Assessment PLANT OVERVIEW TPM Self Assessment Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 9
Courtesy, in part, of Motorola SPS. Thank You! TPM Self Assessment Background: ∆1991 First attempt to implement TPM. ∆ 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. ð Lack of support and involvement results on failing the implementation. Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 10
Courtesy, in part, of Motorola SPS. Thank You! TPM Self Assessment 1996 ∆ One Staff Mgr. is assigned to lead the TPM Implementation plant wide. ∆ A core team is formed on 2Q/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. Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 11
Courtesy, in part, of Motorola SPS. Thank You! Asia Benchmarking PLANT OVERVIEW TPM Self Assessment Asia Benchmarking Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 12
Courtesy, in part, of Motorola SPS. Thank You! TPM Benchmarking Asia Facilities 1996 Facility 1 April Facility 2 May Facility 3 June Committee: 4 Chosen Folks Objective: Learn from Asia success experiences in TPM implementation and come up with directions for Plant implementation. Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 13
Courtesy, in part, of Motorola SPS. Thank You! Benchmarking Conclusions Ø Total management involvement. Ø T.P.M. Manager (dedicated). Ø A well defined implementation process. Ø Provide people with time to work on it. ( 4- 6 Hr./wk ). Ø Each staff has their own T.P.M. Promoter full time. Ø Focused in Consultant X model. Ø Focused in just one product line per area. Ø Budget assigned for consulting and external training. Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 14
Courtesy, in part, of Motorola SPS. Thank You! TPM PLANT OVERVIEW Implementation TPM Self Assessment Asia Benchmarking TPM Implementation Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 15
Courtesy, in part, of Motorola SPS. Thank You! IMPLEMENTATION/CONSULTANT * Q3 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 Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 16
Courtesy, in part, of Motorola SPS. Thank You! 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. Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 17
Courtesy, in part, of Motorola SPS. Thank You! T.P.M. PLANT WIDE STRUCTURE TPM T.P.M. Office Responsible Plant Manager Autonomous Planned Individual 5 ´s Maintenance Maintenance Improvement Quality Early Training Maintenance Equipment Safety People Management Development Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 18
Courtesy, in part, of Motorola SPS. Thank You! PROMOTION STRUCTURE (OVERLAPPING SMALL GROUPS) PLANT MANAGER STAFF MANAGERS OPERATIONS TPM PILLARS & PROMOTION DEPARTMENT OFFICE MANAGERS TPM DEPARTMENT PROMOTERS SUPERVISORS TPM TEAM Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 19
Courtesy, in part, of Motorola SPS. Thank You! VISION STATEMENT: TPM PLANT WIDE IMPLEMENTATION Q1 2000 Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 20
Courtesy, in part, of Motorola SPS. Thank You! T.P.M. IMPLEMENTATION ACTIVITIES MANAGER TEAMS Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 21
Courtesy, in part, of Motorola SPS. Thank You! 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.) Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 22
Courtesy, in part, of Motorola SPS. Thank You! Line and Machine Selection B-820 B-820 Machine 1 Machine 2 N-661 POWER HEATER Machine 3 Machine 4 B-609 B-609 V-701 V-701 Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 23
TPM Implementation Plan 1996 1997 1998 1999 2000 ACTIVITIES Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 DEFINE STRATEGIES PREPARATION MASTER PLAN ORGANIZATION STAGE T INTRODUCTION TRAINING 1 P 2 PUBLICITY 3 M I S MODEL MACHINES T Machine 1 AUTONOMOUS MAINTENANCE M K A Machine 2 & P I R Machine 3 REDUCE 6 BIG LOSSES L C EXTEND SIMILAR MACHINES E T Machine 4 K M EXTEND 30% E IMPLEMENTATION O to N SIMILAR F 50% T T PRODUCTION LINES A F A T R COMPLETE I G IMPLEMENTATION 100% O E DEFINED AREAS N T
TPM 90 Days Explosion Plan October November December ww40 ww41 ww42 ww43 ww44 ww45 ww46 ww47 ww48 ww49 ww50 ww51 ww52 Machine 1 PILOT TEAM Step 3 Start Planned maintenance Start 6 big losses Start Individual Improvement Start 10 Extension teams step 1-2 4 mc 3 mc 3 mc 19 Extension teams Start step 1 7 mc 6 mc 6 mc Machine 2 PILOT TEAM Step 2-3 Start Planned maintenance Start 6 big losses Step 1 Step 2 Individual Improvement Step 1 11 Extension teams step 1-2 B-613 3 mc 2 mc 2 mc B-601 L-604 Machine 3 PILOT TEAM Step 2-3 Start Planned maintenance Start 6 big losses Start Individual Improvement Start 6 Extension teams step 1-2 2 mc 4 mc 2 Extension teams Start step 1 Start Machine 4 PILOT TEAM Step 1-2 Start Planned maintenance Start 6 big losses Start Individual Improvement Start 4 extension teams Start step 1 a-820 a-821 J-701 J-601 PILLARS IMPLEMENTATION MODEL GANTT TPM Activity Board Extension Teams Server Data collection M1 M2 M3 M4 GM Audit Team presentations TPM Office Audit Consultant visit TPM Meeting Local BOOT CAMP TPM MCOE MEETING, JAPAN Pillars meeting
Courtesy, in part, of Motorola SPS. Thank You! T.P.M. TRANSITION CURVE POLICIES DEVELOPMENT T.P.M. PROMOTION DELEGATION T.P.M. PROMOTION OFFICE START INCLUDE T.P.M. IN PERFORMANCE C MANAGEMENT MACHINES MANAGEMENT PLAN. O FOCUS IN FEW EQUIPMENT INCLUDE T.P.M. IN JOB M FOCUS TRAINING DESCRIPTION. M D I SUCCESS STORIES ACCELERATED E T N 5 S´s DEPLOYMENT. M I E A N L CONSULTANT CONSULTANT T IN OUT KICK OFF R E E X S P GOALS SETTING FOR I L ALL ORGANIZATION. S O T R LOOK FOR ADDITIONAL WAYS DEVELOP DATA COLLECTION SYSTEM A A T TO DEPLOY T.P.M. N ATTENTION TO FOCUS TEAMS C I FINISH CONFLICT WITH THE CULTURE TRAINING DEPLOYMENT E O ORGANIZATION ALIGNMENT IMPLEMENTATION PLAN N REWARD SYSTEM RESOURCE IMPLEMENTATION CONTROL CHAOS Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 26
Courtesy, in part, of Motorola SPS. Thank You! KEY GOALS 1.- TOTAL EQUIPMENT EFFECTIVENESS % 85 A) Equipment Breakdown HOURS/MONTH 1/10 B) M.T.B.A. MINUTES 1x10x C) M.T.B.F. HOURS 1x2x 2.- REJECT CAUSED BY LINE EQUIPMENT PPM 1/5 3.- LINE REJECT RATE % 1/5 4.- CYCLE TIME DAYS 0.8X 5.- FATAL ERROR AT CUSTOMER # OF 0 6.- ON TIME DELIVERED % 98 7.- MANUFACTURING COST USD 20% LESS 8.- LABOR PRODUCTIVITY K.UNITS /# OF D/L 2X Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 27
Courtesy, in part, of Motorola SPS. Thank You! AUTONOMOUS MAINTENANCE. MANUFACTURING SPECIALIST Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 28
Courtesy, in part, of Motorola SPS. Thank You! 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. Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 29
Courtesy, in part, of Motorola SPS. Thank You! AUTONOMOUS MAINTENANCE 5 Formats: Daily Cleaning & 6 4 Initial Inspection Hot Spots, CAP-DO 5W´s Develop One Major Problems Point lesson Selection Step # 1 Standardization 7 Cleaning / 3 Put F Tags Initial Cleaning Lubrication Training in Initial Cleaning One Point Lesson (Inspection) 8 2 Photos Before Photos After 1 Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 30
Courtesy, in part, of Motorola SPS. Thank You! AUTONOMOUS MAINTENANCE 5 Failures Analysis 4 Why´s Analysis 6 Put “F” Tags Actions in Sources of Contamination & Hard access areas Step # 2 Find & List Sources of Modify Covers For 3 Areas of Hard Easy Visualization 7 Access Contamination & & Quick Hard Access Areas Disassemble Find & List Sources of Contamination Remove “F” Tags 2 Initial Inspection Final Inspection 8 (Audit) 1 Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 31
Courtesy, in part, of Motorola SPS. Thank You! AUTONOMOUS MAINTENANCE 5 4 Improve time of execution 6 Verify Detail actual time activities Vs estimated 3 Put “F” Tags Step # 3 (Establish time Remove & frequency) 3 Tentative “F” Tags 7 Standards Cleaning / Lubrication Apply activities to implementation similar machines 2 Develop tentative 2 standards 8 1 Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 32
Courtesy, in part, of Motorola SPS. Thank You! TPM Teams Status October 1997 •Number of Hot Spots detected: 284 •Number of Hot Spots solved: 126 •One Point Lesson developed: 44 •One Point Lesson Taught: 34 •Number of teams on TPM: 27 •Teams on step 3: 1 •Teams on step 2: 2 •Teams on step 1: 24 Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 33
Courtesy, in part, of Motorola SPS. Thank You! PLANT OVERVIEW TPM Expansion Plan Self Assessment Asia Benchmarking TPM Implementation Expansion Plan Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 34
Courtesy, in part, of Motorola SPS. Thank You! T.P.M. DEPLOYMENT L I N E F L O W 1 CURRENT EQUIPMENT IN T.P.M. 9 9 SAME KIND OF EQUIPMENT 1997 8 1999/2000 EXPANSION Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 35
Courtesy, in part, of Motorola SPS. Thank You! PROJECTED PROGRESS IN TEAMS Q-1’ 98 Line A.M. STEP # 1 A.M. STEP # 2 A.M. STEP # 3 Wafer Process Line 1 11 16 03 Line 2 03 11 01 Line 3 03 08 01 Line 4 04 01 01 Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 36
Courtesy, in part, of Motorola SPS. Thank You! T.P.M. FOLLOW-UP TEAMS TEAMS TEAMS Consultant X MANAGERS PRESENTATION AUDITS MEETING VISITS PRESENTATION 6 TEAMS 6 TEAMS MONTHLY WEEKLY TWO DAY PER PER EVERY MEETING MONTH MONTH TWO MONTHS Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 37
Courtesy, in part, of Motorola SPS. Thank You! PLANT Pilot Team OVERVIEW TPM Self Assessment Asia Benchmarking Case Study TPM Implementation Expansion Plan Pilot Team Case Study Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 38
Courtesy, in part, of Motorola SPS. Thank You! PILOT MACHINE N-62361 Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 39
Courtesy, in part, of Motorola SPS. Thank You! Defectives 30 25 25 23 23 22 21 20 20 20 18 17 19 15 10 8 9 8 7 7 6 6 6 6 6 5 5 5 5 3 4 3 3 2 4 4 0 N-662361 N-61162 N-634766 JAN 96 FEB MAR APR MAY JUN JUL AUG SEP OCT 96 Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 40
Courtesy, in part, of Motorola SPS. % T. C. Thank You! DOWN TIME MAR ENE./96 MAY JUL OCT./96 ABR FEB JUN SEP AGO 25% 23% 23% 20% 20% 20% 18% 18% 18% 17% 15% 15% N-662361 12% 10% 5% 0% % T. C. ABR FEB JUN SEP ENE./96 MAR AGO MAY JUL OCT./96 25% 20% 15% N-663242 10% 12% 11% 10% 11% 8% 9% 7% 8% 10% 6% 5% 0% % T. C. FEB JUN MAR AGO OCT./96 MAY ENE./96 JUL ABR SEP 25,00% 20,00% 15,00% N-649666 10,00% 9% 7,50% 8% 8% 7% 6% 5,00% 4% 5% 5% 3% 0,00% Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 41
Courtesy, in part, of Motorola SPS. Thank You! CLEANING IS INSPECTION.... 5’S AUTONOMOUS MAINTENANCE Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 42
Courtesy, in part, of Motorola SPS. Thank You! INSPECTION IS DETECTION. CRASH Broken Part Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 43
Courtesy, in part, of Motorola SPS. Thank You! PRESSURE CORRECT INCORRECT TO MUCH TO MUCH PRESSURE PRESSURE CORRECT ALIGNMENT INCORRECT GAUGE NO Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 44
Courtesy, in part, of Motorola SPS. Thank You! CORRECT CENTERING INCORRECT Dummy Part CORRECT SYMMETRY INCORRECT BENT BENT Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 45
Courtesy, in part, of Motorola SPS. Thank You! CONTACT INCORRECT CORRECT Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 46
Courtesy, in part, of Motorola SPS. Thank You! TO STANDARDIZE AND PREVENT RECURRENCE One Point Lesson Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 47
Courtesy, in part, of Motorola SPS. Thank You! MACHINE PERFORMANCE Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 48
Courtesy, in part, of Motorola SPS. Thank You! Defectives 25 23 20 18 15 “ZERO” Defectives 10 Abr May Ago Jul Oct-96 Feb Mar Jun Jan-97 Sep-96 Dec-96 Sep 10 6 5 3 2 1 0 0 0 0 0 0 P.C. BOARD DOWN TIME % D.T. DAMAGED 25% Nov-96 Apr Sep May Aug Jul Jan-97 Dec-96 Feb Mar Jun Oct-96 20% 20% 18% 15% 15% 12% 10% 9% 8% 7% 6% 5% 5% 4% 3% 3% 0% Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 49
Courtesy, in part, of Motorola SPS. Thank You! WHAT IS NEXT? 6 Big Losses LINK 4 4 Autonomous Planned Maintenance 3 Maintenance Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 50
Courtesy, in part, of Motorola SPS. Thank You! Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 51

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Tpm

  • 1. Courtesy, in part, of Motorola SPS. Thank You! Welcome To Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 1
  • 2. Courtesy, in part, of Motorola SPS. Thank You! 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. Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 2
  • 3. Courtesy, in part, of Motorola SPS. Thank You! 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 Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 3
  • 4. Courtesy, in part, of Motorola SPS. Thank You! T.P.M. = Medical Science of Equipment PRODUCTION Foton AUTOMATION B-820 VIDEO-AUTO DIE-BONDER MODEL 8030A POWER HEATER Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 4
  • 5. Courtesy, in part, of Motorola SPS. Thank You! 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 Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 5
  • 6. Courtesy, in part, of Motorola SPS. Thank You! PILLARS OF TPM I P A M M M S E I M E M U A A A T A A N P O A T I I P I R F R Q D R P N O N N L N A E L U I O L A N T T A T I T Y A V V E G O E E E N Y L N I D E E E M N I N N N D I E M M Q O A T A E A U N V E E E U U N Y N D N A G E N N H I S C C C L L T T S P E E E O P 5S´s Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 6
  • 7. Courtesy, in part, of Motorola SPS. Thank You! T.P.M. Total Productive Manufacturing People , Equipment and Product Improvement by Working Together. EXCELLENCE Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 7
  • 8. Courtesy, in part, of Motorola SPS. Thank You! PLANT OVERVIEW PLANT OVERVIEW Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 8
  • 9. Courtesy, in part, of Motorola SPS. Thank You! TPM Self Assessment PLANT OVERVIEW TPM Self Assessment Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 9
  • 10. Courtesy, in part, of Motorola SPS. Thank You! TPM Self Assessment Background: ∆1991 First attempt to implement TPM. ∆ 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. ð Lack of support and involvement results on failing the implementation. Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 10
  • 11. Courtesy, in part, of Motorola SPS. Thank You! TPM Self Assessment 1996 ∆ One Staff Mgr. is assigned to lead the TPM Implementation plant wide. ∆ A core team is formed on 2Q/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. Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 11
  • 12. Courtesy, in part, of Motorola SPS. Thank You! Asia Benchmarking PLANT OVERVIEW TPM Self Assessment Asia Benchmarking Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 12
  • 13. Courtesy, in part, of Motorola SPS. Thank You! TPM Benchmarking Asia Facilities 1996 Facility 1 April Facility 2 May Facility 3 June Committee: 4 Chosen Folks Objective: Learn from Asia success experiences in TPM implementation and come up with directions for Plant implementation. Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 13
  • 14. Courtesy, in part, of Motorola SPS. Thank You! Benchmarking Conclusions Ø Total management involvement. Ø T.P.M. Manager (dedicated). Ø A well defined implementation process. Ø Provide people with time to work on it. ( 4- 6 Hr./wk ). Ø Each staff has their own T.P.M. Promoter full time. Ø Focused in Consultant X model. Ø Focused in just one product line per area. Ø Budget assigned for consulting and external training. Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 14
  • 15. Courtesy, in part, of Motorola SPS. Thank You! TPM PLANT OVERVIEW Implementation TPM Self Assessment Asia Benchmarking TPM Implementation Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 15
  • 16. Courtesy, in part, of Motorola SPS. Thank You! IMPLEMENTATION/CONSULTANT * Q3 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 Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 16
  • 17. Courtesy, in part, of Motorola SPS. Thank You! 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. Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 17
  • 18. Courtesy, in part, of Motorola SPS. Thank You! T.P.M. PLANT WIDE STRUCTURE TPM T.P.M. Office Responsible Plant Manager Autonomous Planned Individual 5 ´s Maintenance Maintenance Improvement Quality Early Training Maintenance Equipment Safety People Management Development Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 18
  • 19. Courtesy, in part, of Motorola SPS. Thank You! PROMOTION STRUCTURE (OVERLAPPING SMALL GROUPS) PLANT MANAGER STAFF MANAGERS OPERATIONS TPM PILLARS & PROMOTION DEPARTMENT OFFICE MANAGERS TPM DEPARTMENT PROMOTERS SUPERVISORS TPM TEAM Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 19
  • 20. Courtesy, in part, of Motorola SPS. Thank You! VISION STATEMENT: TPM PLANT WIDE IMPLEMENTATION Q1 2000 Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 20
  • 21. Courtesy, in part, of Motorola SPS. Thank You! T.P.M. IMPLEMENTATION ACTIVITIES MANAGER TEAMS Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 21
  • 22. Courtesy, in part, of Motorola SPS. Thank You! 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.) Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 22
  • 23. Courtesy, in part, of Motorola SPS. Thank You! Line and Machine Selection B-820 B-820 Machine 1 Machine 2 N-661 POWER HEATER Machine 3 Machine 4 B-609 B-609 V-701 V-701 Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 23
  • 24. TPM Implementation Plan 1996 1997 1998 1999 2000 ACTIVITIES Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 DEFINE STRATEGIES PREPARATION MASTER PLAN ORGANIZATION STAGE T INTRODUCTION TRAINING 1 P 2 PUBLICITY 3 M I S MODEL MACHINES T Machine 1 AUTONOMOUS MAINTENANCE M K A Machine 2 & P I R Machine 3 REDUCE 6 BIG LOSSES L C EXTEND SIMILAR MACHINES E T Machine 4 K M EXTEND 30% E IMPLEMENTATION O to N SIMILAR F 50% T T PRODUCTION LINES A F A T R COMPLETE I G IMPLEMENTATION 100% O E DEFINED AREAS N T
  • 25. TPM 90 Days Explosion Plan October November December ww40 ww41 ww42 ww43 ww44 ww45 ww46 ww47 ww48 ww49 ww50 ww51 ww52 Machine 1 PILOT TEAM Step 3 Start Planned maintenance Start 6 big losses Start Individual Improvement Start 10 Extension teams step 1-2 4 mc 3 mc 3 mc 19 Extension teams Start step 1 7 mc 6 mc 6 mc Machine 2 PILOT TEAM Step 2-3 Start Planned maintenance Start 6 big losses Step 1 Step 2 Individual Improvement Step 1 11 Extension teams step 1-2 B-613 3 mc 2 mc 2 mc B-601 L-604 Machine 3 PILOT TEAM Step 2-3 Start Planned maintenance Start 6 big losses Start Individual Improvement Start 6 Extension teams step 1-2 2 mc 4 mc 2 Extension teams Start step 1 Start Machine 4 PILOT TEAM Step 1-2 Start Planned maintenance Start 6 big losses Start Individual Improvement Start 4 extension teams Start step 1 a-820 a-821 J-701 J-601 PILLARS IMPLEMENTATION MODEL GANTT TPM Activity Board Extension Teams Server Data collection M1 M2 M3 M4 GM Audit Team presentations TPM Office Audit Consultant visit TPM Meeting Local BOOT CAMP TPM MCOE MEETING, JAPAN Pillars meeting
  • 26. Courtesy, in part, of Motorola SPS. Thank You! T.P.M. TRANSITION CURVE POLICIES DEVELOPMENT T.P.M. PROMOTION DELEGATION T.P.M. PROMOTION OFFICE START INCLUDE T.P.M. IN PERFORMANCE C MANAGEMENT MACHINES MANAGEMENT PLAN. O FOCUS IN FEW EQUIPMENT INCLUDE T.P.M. IN JOB M FOCUS TRAINING DESCRIPTION. M D I SUCCESS STORIES ACCELERATED E T N 5 S´s DEPLOYMENT. M I E A N L CONSULTANT CONSULTANT T IN OUT KICK OFF R E E X S P GOALS SETTING FOR I L ALL ORGANIZATION. S O T R LOOK FOR ADDITIONAL WAYS DEVELOP DATA COLLECTION SYSTEM A A T TO DEPLOY T.P.M. N ATTENTION TO FOCUS TEAMS C I FINISH CONFLICT WITH THE CULTURE TRAINING DEPLOYMENT E O ORGANIZATION ALIGNMENT IMPLEMENTATION PLAN N REWARD SYSTEM RESOURCE IMPLEMENTATION CONTROL CHAOS Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 26
  • 27. Courtesy, in part, of Motorola SPS. Thank You! KEY GOALS 1.- TOTAL EQUIPMENT EFFECTIVENESS % 85 A) Equipment Breakdown HOURS/MONTH 1/10 B) M.T.B.A. MINUTES 1x10x C) M.T.B.F. HOURS 1x2x 2.- REJECT CAUSED BY LINE EQUIPMENT PPM 1/5 3.- LINE REJECT RATE % 1/5 4.- CYCLE TIME DAYS 0.8X 5.- FATAL ERROR AT CUSTOMER # OF 0 6.- ON TIME DELIVERED % 98 7.- MANUFACTURING COST USD 20% LESS 8.- LABOR PRODUCTIVITY K.UNITS /# OF D/L 2X Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 27
  • 28. Courtesy, in part, of Motorola SPS. Thank You! AUTONOMOUS MAINTENANCE. MANUFACTURING SPECIALIST Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 28
  • 29. Courtesy, in part, of Motorola SPS. Thank You! 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. Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 29
  • 30. Courtesy, in part, of Motorola SPS. Thank You! AUTONOMOUS MAINTENANCE 5 Formats: Daily Cleaning & 6 4 Initial Inspection Hot Spots, CAP-DO 5W´s Develop One Major Problems Point lesson Selection Step # 1 Standardization 7 Cleaning / 3 Put F Tags Initial Cleaning Lubrication Training in Initial Cleaning One Point Lesson (Inspection) 8 2 Photos Before Photos After 1 Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 30
  • 31. Courtesy, in part, of Motorola SPS. Thank You! AUTONOMOUS MAINTENANCE 5 Failures Analysis 4 Why´s Analysis 6 Put “F” Tags Actions in Sources of Contamination & Hard access areas Step # 2 Find & List Sources of Modify Covers For 3 Areas of Hard Easy Visualization 7 Access Contamination & & Quick Hard Access Areas Disassemble Find & List Sources of Contamination Remove “F” Tags 2 Initial Inspection Final Inspection 8 (Audit) 1 Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 31
  • 32. Courtesy, in part, of Motorola SPS. Thank You! AUTONOMOUS MAINTENANCE 5 4 Improve time of execution 6 Verify Detail actual time activities Vs estimated 3 Put “F” Tags Step # 3 (Establish time Remove & frequency) 3 Tentative “F” Tags 7 Standards Cleaning / Lubrication Apply activities to implementation similar machines 2 Develop tentative 2 standards 8 1 Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 32
  • 33. Courtesy, in part, of Motorola SPS. Thank You! TPM Teams Status October 1997 •Number of Hot Spots detected: 284 •Number of Hot Spots solved: 126 •One Point Lesson developed: 44 •One Point Lesson Taught: 34 •Number of teams on TPM: 27 •Teams on step 3: 1 •Teams on step 2: 2 •Teams on step 1: 24 Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 33
  • 34. Courtesy, in part, of Motorola SPS. Thank You! PLANT OVERVIEW TPM Expansion Plan Self Assessment Asia Benchmarking TPM Implementation Expansion Plan Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 34
  • 35. Courtesy, in part, of Motorola SPS. Thank You! T.P.M. DEPLOYMENT L I N E F L O W 1 CURRENT EQUIPMENT IN T.P.M. 9 9 SAME KIND OF EQUIPMENT 1997 8 1999/2000 EXPANSION Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 35
  • 36. Courtesy, in part, of Motorola SPS. Thank You! PROJECTED PROGRESS IN TEAMS Q-1’ 98 Line A.M. STEP # 1 A.M. STEP # 2 A.M. STEP # 3 Wafer Process Line 1 11 16 03 Line 2 03 11 01 Line 3 03 08 01 Line 4 04 01 01 Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 36
  • 37. Courtesy, in part, of Motorola SPS. Thank You! T.P.M. FOLLOW-UP TEAMS TEAMS TEAMS Consultant X MANAGERS PRESENTATION AUDITS MEETING VISITS PRESENTATION 6 TEAMS 6 TEAMS MONTHLY WEEKLY TWO DAY PER PER EVERY MEETING MONTH MONTH TWO MONTHS Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 37
  • 38. Courtesy, in part, of Motorola SPS. Thank You! PLANT Pilot Team OVERVIEW TPM Self Assessment Asia Benchmarking Case Study TPM Implementation Expansion Plan Pilot Team Case Study Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 38
  • 39. Courtesy, in part, of Motorola SPS. Thank You! PILOT MACHINE N-62361 Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 39
  • 40. Courtesy, in part, of Motorola SPS. Thank You! Defectives 30 25 25 23 23 22 21 20 20 20 18 17 19 15 10 8 9 8 7 7 6 6 6 6 6 5 5 5 5 3 4 3 3 2 4 4 0 N-662361 N-61162 N-634766 JAN 96 FEB MAR APR MAY JUN JUL AUG SEP OCT 96 Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 40
  • 41. Courtesy, in part, of Motorola SPS. % T. C. Thank You! DOWN TIME MAR ENE./96 MAY JUL OCT./96 ABR FEB JUN SEP AGO 25% 23% 23% 20% 20% 20% 18% 18% 18% 17% 15% 15% N-662361 12% 10% 5% 0% % T. C. ABR FEB JUN SEP ENE./96 MAR AGO MAY JUL OCT./96 25% 20% 15% N-663242 10% 12% 11% 10% 11% 8% 9% 7% 8% 10% 6% 5% 0% % T. C. FEB JUN MAR AGO OCT./96 MAY ENE./96 JUL ABR SEP 25,00% 20,00% 15,00% N-649666 10,00% 9% 7,50% 8% 8% 7% 6% 5,00% 4% 5% 5% 3% 0,00% Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 41
  • 42. Courtesy, in part, of Motorola SPS. Thank You! CLEANING IS INSPECTION.... 5’S AUTONOMOUS MAINTENANCE Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 42
  • 43. Courtesy, in part, of Motorola SPS. Thank You! INSPECTION IS DETECTION. CRASH Broken Part Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 43
  • 44. Courtesy, in part, of Motorola SPS. Thank You! PRESSURE CORRECT INCORRECT TO MUCH TO MUCH PRESSURE PRESSURE CORRECT ALIGNMENT INCORRECT GAUGE NO Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 44
  • 45. Courtesy, in part, of Motorola SPS. Thank You! CORRECT CENTERING INCORRECT Dummy Part CORRECT SYMMETRY INCORRECT BENT BENT Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 45
  • 46. Courtesy, in part, of Motorola SPS. Thank You! CONTACT INCORRECT CORRECT Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 46
  • 47. Courtesy, in part, of Motorola SPS. Thank You! TO STANDARDIZE AND PREVENT RECURRENCE One Point Lesson Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 47
  • 48. Courtesy, in part, of Motorola SPS. Thank You! MACHINE PERFORMANCE Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 48
  • 49. Courtesy, in part, of Motorola SPS. Thank You! Defectives 25 23 20 18 15 “ZERO” Defectives 10 Abr May Ago Jul Oct-96 Feb Mar Jun Jan-97 Sep-96 Dec-96 Sep 10 6 5 3 2 1 0 0 0 0 0 0 P.C. BOARD DOWN TIME % D.T. DAMAGED 25% Nov-96 Apr Sep May Aug Jul Jan-97 Dec-96 Feb Mar Jun Oct-96 20% 20% 18% 15% 15% 12% 10% 9% 8% 7% 6% 5% 5% 4% 3% 3% 0% Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 49
  • 50. Courtesy, in part, of Motorola SPS. Thank You! WHAT IS NEXT? 6 Big Losses LINK 4 4 Autonomous Planned Maintenance 3 Maintenance Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 50
  • 51. Courtesy, in part, of Motorola SPS. Thank You! Cayman Systems USA 513 777-3394 ©1998 Revision A 980810 TPM Awareness Information 51