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In order to understand anything, you must not try to understand everything Aristotle

In order to understand anything, you must not try to understand everything Aristotle. efficiency . 1 universality. focus !. Our focus today, Total Productive Maintenance. Thinking Hats.

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In order to understand anything, you must not try to understand everything Aristotle

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  1. In order to understand anything, you must not try to understand everything Aristotle

  2. efficiency  1 universality

  3. focus!

  4. Our focus today,Total Productive Maintenance

  5. Thinking Hats

  6. Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance, Maintenance Maintenance Breakdown Predictive Preventive

  7. ? Total Productive Maintenance Keeping the current plant and equipment at its highest productive level through cooperation of all areas of the organization

  8. ! Maintaining & improving equipment capacityMaintaining equipment for lifeUsing support from all areas of operationsEncourage input from all employeesUsing teams for continuous improvement

  9. DowntimeLOSSES VARIOUS LOSS AREAS

  10. Planned Start-ups Shift Changes Coffee and Lunch Breaks Planned maintenance shutdowns Downtime

  11. Unplanned Equipment breakdown Changeovers Lack of materials Downtime

  12. Reduced Speed Idling and minor stoppages Slow downs LOSSES

  13. Poor Quality Process nonconformities Scrap LOSSES

  14. Calculating Downtime Losses Downtime Losses are measured by Equipment availability A= (T/P) x 100 A = Availability T = Operating Time (P-D) P = Planned Operating time D = Downtime

  15. Calculating Reduced Speed Losses Reduced Speed losses measured by performance efficiency E = { ( C x N ) / T } x 100 E = Performance Efficiency C = Theoretical Cycle Time N = Processed Amount (Quantity) T = Operating Time (P-D)

  16. Calculating Poor Quality Losses Poor Quality Losses measured by rate of quality products produced R = { ( N – Q ) / N } x 100 R = Rate of Quality Products N = Processed Amount (Quantity) Q = Nonconformities

  17. Calculating Equipment Effectiveness Equipment Effectiveness is the products of previous metrics EE = A x E x R EE = Equipment Effectiveness

  18. TARGETEquipmentEffectiveness 85%

  19. Hands-on with Calculations TARGETEquipment Effectiveness Last week’s production numbers on manufacturing center JL58 were as follows: Scheduled operations = 10 hours/day; 5 days/week Manufacturing downtime due to meetings, Material outages, training, breaks and so forth = 410 minutes/week Maintenance downtime scheduled and equipment breakdown = 227 minutes/week Theoretical (Standard) Cycle time = 0.5 minutes/unit Production for the week = 4450 units Defective parts made = 15 units P = 10 hours/day x 5 days/week x 60 minutes/hour = 3000 minutes/week D = 410 minutes/week + 227 minutes/week = 637 minutes/week T = ( P – D ) = 3000 – 637 = 2363 minutes Please calculate A = ( T / P ) x 100 (Equipment Availability) E = { (C x N) / T } x 100 (Performance Efficiency) R = {( N – Q ) / N } x 100 (Quality Products produced) EE = A x E x R (Equipment Efficiency) 85%

  20. Target Equipment Efficiency 85% HOWdowe achieve 85% EE?

  21. Break We however request Green Hats to start thinking about the problem, when we’ll return, we’ll discuss about the ideas given out by the Green Hats.

  22. TARGETEquipmentEffectiveness 85%

  23. Total Productive Maintenance

  24. Total Productive Maintenance Recipe Learn the new philosophy Promote the new philosophy Fund the training and train everyone Identify areas of the needed improvement Formulate performance goals Develop implementation plan Establish autonomous work groups

  25. Life is the art of drawing sufficient conclusionsfrom insufficient premisesSamuel Butler

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