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TPM: Focused Improvement (Kobetsu Kaizen)

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TPM: Focused Improvement (Kobetsu Kaizen)

[Note: This is a partial preview. To download this presentation, visit:
https://www.oeconsulting.com.sg/training-presentations]

Focused Improvement is one of the key pillars of TPM. Also known as Kobetsu Kaizen in Japanese, this presentation provides shopfloor TPM teams, including production workers, maintenance technicians, engineers, and managers a strong framework for further improving equipment performance as well as eliminating the 16 big losses.

As distinguished from Autonomous Maintenance, in which the main goal is to restore basic conditions to prevent accelerated deterioration, Focused Improvement looks at weaknesses that everyone previously thought were unavoidable.

Developed by our JIPM-certified TPM Instructor, this training presentation teaches you the knowledge and skills for planning, organizing and implementing Focused Improvement activities in the workplace. It includes the step by step process and the common analytical tools and techniques for Focused Improvement. 

LEARNING OBJECTIVES​

1. Understand what is Focused Improvement and why it is important in TPM implementation
2. Acquire knowledge on how to plan and organize Focused Improvement activities
3. Describe the Focused Improvement approach and the common analytical tools
4. Gain practical tips for sustaining Focused Improvement activities and the key factors for success

CONTENTS

1. Introduction to Focused Improvement
2. What is Focused Improvement?
3. Planning and Organizing for Focused Improvement
4. The 8 Steps of Focused Improvement
5. Common Tools & Techniques for Focused Improvement

To download this presentation, visit:
https://www.oeconsulting.com.sg/training-presentations

[Note: This is a partial preview. To download this presentation, visit:
https://www.oeconsulting.com.sg/training-presentations]

Focused Improvement is one of the key pillars of TPM. Also known as Kobetsu Kaizen in Japanese, this presentation provides shopfloor TPM teams, including production workers, maintenance technicians, engineers, and managers a strong framework for further improving equipment performance as well as eliminating the 16 big losses.

As distinguished from Autonomous Maintenance, in which the main goal is to restore basic conditions to prevent accelerated deterioration, Focused Improvement looks at weaknesses that everyone previously thought were unavoidable.

Developed by our JIPM-certified TPM Instructor, this training presentation teaches you the knowledge and skills for planning, organizing and implementing Focused Improvement activities in the workplace. It includes the step by step process and the common analytical tools and techniques for Focused Improvement. 

LEARNING OBJECTIVES​

1. Understand what is Focused Improvement and why it is important in TPM implementation
2. Acquire knowledge on how to plan and organize Focused Improvement activities
3. Describe the Focused Improvement approach and the common analytical tools
4. Gain practical tips for sustaining Focused Improvement activities and the key factors for success

CONTENTS

1. Introduction to Focused Improvement
2. What is Focused Improvement?
3. Planning and Organizing for Focused Improvement
4. The 8 Steps of Focused Improvement
5. Common Tools & Techniques for Focused Improvement

To download this presentation, visit:
https://www.oeconsulting.com.sg/training-presentations

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TPM: Focused Improvement (Kobetsu Kaizen)

  1. 1. © Operational Excellence Consulting. All rights reserved. © Operational Excellence Consulting. All rights reserved. Focused Improvement (KOBETSU KAIZEN)
  2. 2. © Operational Excellence Consulting. All rights reserved. 2 Learning Objectives Understand what is Focused Improvement and why it is important in TPM implementation Describe the Focused Improvement approach and the common analytical tools Acquire knowledge on how to plan and organize for Focused Improvement activities Gain practical tips for sustaining Focused Improvement activities and the key factors for success NOTE: This is a PARTIAL PREVIEW. To download the complete presentation, please visit: https://www.oeconsulting.com.sg
  3. 3. © Operational Excellence Consulting. All rights reserved. 3 Contents What is Focused Improvement? 2 Planning & Organizing for Focused Improvement 3 Introduction to Focused Improvement 1 The 8 Steps of Focused Improvement 4 Common Tools & Techniques for Focused Improvement 5
  4. 4. © Operational Excellence Consulting. All rights reserved. 4 Focused Improvement is One of the Pillars of the TPM Excellence Framework Overview of TPM Office TPM Safety, Health & Environment Autonomous Maintenance Planned Maintenance Focused Improvement Early Equipment Management Quality Maintenance Education & Training 5S & Visual Management TPM Goals: Zero Defects, Zero Breakdowns, Zero Accidents Focused Improvement involves targeted projects to reduce specific losses.
  5. 5. © Operational Excellence Consulting. All rights reserved. 5 The Effects of Much Conventional Improvement Activity are Transitory Time Event #1 Event #2 What Standard should be Maintenance Maintenance Event #3 Work Standard What Standard should be Output What actually becomes the Standard when people do not sustain the changes There was a strong tendency for improvements not to be capable of being maintained or properly established.
  6. 6. © Operational Excellence Consulting. All rights reserved. 6 To Keep Companies’ Results Perpetually Trending Upwards, Two Abilities are Needed: the Ability to Maintain and Improve Time Innovation New Standard What the Standard becomes Maintain the Standard: Autonomous Maintenance Current Work Standard Gradually Improve the Standard: Focused Improvement Next Innovation Productive Potential of Underutilized People Output In TPM, activities are organized to ensure that the benefits of Focused Improvements are upheld, principally through Autonomous Maintenance.
  7. 7. © Operational Excellence Consulting. All rights reserved. 7 Focused Improvement Aims to Increase Production Efficiencies by Eliminating the 16 Big Losses Equipment Losses 1. Breakdown Loss 2. Set Up & Adjustment Loss 3. Tool Replacement Loss 4. Start Up Loss 5. Minor Stoppage & Idling Loss 6. Speed Reduction Loss 7. Defect & Rework Loss 8. Shutdown Loss Manpower Losses 1. Management Loss 2. Motion Loss 3. Line Organization Loss 4. Logistics Loss 5. Measurement & Adjustment Loss Manpower Losses 1. Yield Loss 2. Energy Loss 3. Tool & Jig Loss Note: Refer to the Appendix for definitions on the 16 big losses
  8. 8. © Operational Excellence Consulting. All rights reserved. 8 Difference Between Autonomous Maintenance and Focused Improvement Autonomous Maintenance § Prevents accelerated deterioration of machine parts § Provides the underpinning to uphold the benefits of Focused Improvement over the long term Focused Improvement § Addresses the 16 big losses § Addresses specific equipment-related losses that reduce Overall Equipment Effectiveness (OEE)
  9. 9. © Operational Excellence Consulting. All rights reserved. 9 The Distribution of Maintenance Work vs. Improvement Work Depends on the Job Functions Top Management Middle Management Supervisors & Team Leaders Frontline Workers Innovation Maintenance Improvement Source: Adapted from Masaaki Imai Focused Improvement activities cut across all job functions.
  10. 10. © Operational Excellence Consulting. All rights reserved. 10 Focused Improvement is a Cross-functional Management Activity Improvement Management Maintenance Management Improvement Maintenance Quality Cost Delivery Cross-functional management Line organization Policy deployment Routine (daily) management Small-group activities Individual suggestions Source: Adapted from Masaaki Imai
  11. 11. © Operational Excellence Consulting. All rights reserved. 11 How Focused Improvement Fits with the Other TPM Pillars Safety, Health & Environment Quality Maintenance Planned Maintenance Early Equipment Management Office TPM Focused Improvement TPM Goals: Zero Defects, Zero Breakdowns, Zero Accidents Autonomous Maintenance Education & Training Focused Improvement should be implemented after companies have attained a basic level with Autonomous Maintenance & Planned Maintenance.
  12. 12. © Operational Excellence Consulting. All rights reserved. 12 What is Focused Improvement? § Focused Improvement is also called “Kobetsu Kaizen” in Japanese § The implementation strategy of Focused Improvement is to prioritize the most important losses and then eliminate them § It is based on the system thinking approach that focuses on improvement of the whole system with the cumulative effort of a team Focused Improvement
  13. 13. © Operational Excellence Consulting. All rights reserved. 13 What is Focused Improvement? § Focused improvement includes all activities that maximize the overall effectiveness of equipment, processes and plants through uncompromising elimination of the 16 big losses § The improvement work is done by small groups of people working together § Teams are made from every level of organization, managers, engineers, staff, technicians and operators § The improvement process follows a structured approach that uses the Plan-Do-Check Act (PDCA) cycle to identify and eliminate issues in a systematic way Focused Improvement
  14. 14. © Operational Excellence Consulting. All rights reserved. 14 Objective of Focused Improvement Focused Improvement The goal is to maximize the effectiveness and efficiencies of the lines, processes and equipment and minimize the company’s losses and waste.
  15. 15. © Operational Excellence Consulting. All rights reserved. 15 Benefits of Focused Improvement § Improving efficiency by reducing defects in products, processes and system § The Focused Improvement pillar ensures that the approach taken is consistent and repeatable to assure sustainability § Recurring problems are identified and resolved by cross-functional teams § Combines the collective talents of a company to create an engine for continuous improvement § Facilitates engineers and technical staff to upgrade their analytical skills in problem solving and improving OEE Focused Improvement
  16. 16. © Operational Excellence Consulting. All rights reserved. 16 TPM Implementation Structure with Focused Improvement as One of the Key Pillars TPM Responsible (Plant Manager) Planned Maintenance Focused Improvement Education & Training Autonomous Maintenance Safety, Health & Environment Early Equipment Management Office TPM Quality Maintenance TPM Promotion Office The company should focus on these four pillars during the first three years of TPM implementation
  17. 17. © Operational Excellence Consulting. All rights reserved. 17 Different Levels of Teams Overlap to Permit Communication and Coordination Efforts Division Manager Area Manager Department Manager Department Manager Department Manager Team Leader Team Leader Team Leader Operators TPM Promotion Office Plant Manager TPM Steering Committee Chairperson of Focused Improvement Pillar Team leader and members of each Focused Improvement project team are drawn from different levels of the organization structure Source: Adapted from TPM Team Guide, Productivity Press Development Team
  18. 18. © Operational Excellence Consulting. All rights reserved. 18 Getting Started: How to Implement Focused Improvement Select model line, process or equipment Form project team Identify & verify the 16 big losses Decide on topic and draw up action plan Implement Focused Improvement project Improve line, process or equipment reliability Increase production efficiency
  19. 19. © Operational Excellence Consulting. All rights reserved. 19 8 Steps of Focused Improvement § The 8 steps of Focused Improvement provide a systematic approach to loss elimination § It is based on the Plan-Do- Check-Act (PDCA) model § The process can be used to improve OEE and eliminate the 16 big losses § It is used with analytical tools (e.g. IE tools, QC tools, P-M analysis, etc.) to solve problems Plan Do Check Act
  20. 20. © Operational Excellence Consulting. All rights reserved. 20 The 8 Steps of Focused Improvement Select the Improvement Topic Understand the Situation Expose & Eliminate Abnormalities Analyze Causes Plan Improvements Implement Improvements Check Results 1 2 3 4 5 6 7 Consolidate Gains 8
  21. 21. © Operational Excellence Consulting. All rights reserved. 21 Example of 5 Why Analysis Why? Answer 1 Why is there oil on the floor? Oil leaks from the cylinder rod when activated. 2 Why did oil leak? The O-ring was cut. 3 Why was the O-ring cut? The rod was flawed. 4 Why was the rod flawed? Dirt in the oil abrades the rod. 5 Why did dirt get in the oil? There are holes and gaps on the upper plate of the tank. Source: OEE for Operators, Productivity Press Development Team
  22. 22. © Operational Excellence Consulting. All rights reserved. 22 Basic Steps of P-M Analysis P-M Analysis Defining the essential or constituent conditions underlying the abnormal phenomena 2 Identifying all factors that contribute to the phenomena in terms of the 4M framework 3 Physically analyzing chronic problems according to the machine’s operating principles 1
  23. 23. © Operational Excellence Consulting. All rights reserved. 23 How to Sustain TPM & Focused Improvement Activities § Engaging employees § Aim for early success § Providing active leadership § Share success stories § Rewards and recognition § Continuously reduce the 16 big losses § Evolving the TPM initiative over time and integration with Lean
  24. 24. © Operational Excellence Consulting. All rights reserved. 24 Critical Success Factors § Long term commitment § Measure and improve OEE § Start with 5S, then move to Autonomous and Preventive Maintenance and Focused Improvement § Launch kaizen events and build teamwork § Apply other tools as needed, e.g. SMED § Celebrate small successes
  25. 25. © Operational Excellence Consulting. All rights reserved. 25 Operational Excellence Consulting is a management training and consulting firm that assists organizations in improving business performance and effectiveness. Based in Singapore, the firm’s mission is to create business value for organizations through innovative design and operational excellence management training and consulting solutions. For more information, please visit www.oeconsulting.com.sg

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