Courtesy, in part, of Motorola SPS. Thank You! Welcome To. Cayman Systems USA Revision A TPM Awareness Information

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1 Welcome To 1

2 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 DVLOPMNT PROGRAM Implementing Total Productive Maintenance Seiichi Nakajima. 2

3 WHAT IS T.P.M.?? Definition of T.P.M : T.P.M. IS: A PRODUCTIV MANUFACTURING SYSTM with the TOTAL Participation of: Managers, Supervisors, ngineers, Technicians and Operators. T.P.M. Includes the Following Benefits: Maximize Overall quipment ffectiveness stablishment a Complete System of Maintenance for the Machine ntire Life Create a Better Work nvironment, Promoting the Participation for All mployees 3

4 T.P.M. = Medical Science of quipment PRODUCTION Foton AUTOMATION B-820 VIDO-AUTO DI-BONDR MODL 8030A POWR HATR 4

5 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 arly quipment Management ducation/training (People Development) Safety 5

6 6 Courtesy, in part, of Motorola SPS. PILLARS OF TPM S A F T Y H S T R A I N I N G M A N A G M N T A R L Y Q U I P M A I N T N A N C P L A N N D M A I N T N A N C Q U A L I T Y A U T O N O M O U S M A I N T N A N C I N D I V I D U A L I M P R O V M N T 5S s P O P L D V L O P

7 T.P.M. Total Productive Manufacturing People, quipment and Product Improvement by Working Together. XCLLNC 7

8 PLANT OVRVIW PLANT OVRVIW 8

9 TPM Self Assessment PLANT OVRVIW TPM Self Assessment 9

10 TPM Self Assessment Background: 1991 First attempt to implement TPM. TPM consultant provides training to selected Managers, Supervisors and ngineers. 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 on failing the implementation. 10

11 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. quipment conditions analysis performed. Most of the teams cover the initial cleaning. Activities are focused on six big losses detected and 5 S s implementation. 11

12 Asia Benchmarking PLANT OVRVIW TPM Self Assessment Asia Benchmarking 12

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

14 Benchmarking Conclusions Total management involvement. T.P.M. Manager (dedicated). A well defined implementation process. Provide people with time to work on it. ( 4-6 Hr./wk ). ach 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. 14

15 TPM PLANT OVRVIW Implementation TPM Self Assessment Asia Benchmarking TPM Implementation 15

16 IMPLMNTATION/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 16

17 T.P.M. POLICY Courtesy, in part, of Motorola SPS. # STABLISH AN INTGRATD STRUCTUR TO PROMOT T.P.M. AS A COMPANY CULTUR. # MAXIMIZ OVRALL QUIPMNT FFCTIVNSS # TOTAL MPLOY INVOLVMNT. # CULTIVAT QUIPMNT & PROCSS RLATD XPRTIS THROUGHOUT SHOP FLOOR. ( Autonomous Maintenance, Planned Maintenance etc..) # STABLISH A RLIABILITY AND MAINTAINABILITY SYSTM TO MAXIMIZ QUIPMNT LIF TIM. (Planned Maintenance Autonomous Maintenance, Individual Improvement, arly quipment Management.) # ALL MPLOYS MUST PARTICIPAT IN T.P.M TRAINING PROGRAM. # ALL ARAS MUST FOLLOW T.P.M. STABLISHD GUID LINS. # DPARTMNT HAD IS RSPONSIBL TO ACCOMPLISH AND SUPPORT T.P.M. GOALS. 17

18 T.P.M. PLANT WID STRUCTUR T.P.M. Office TPM Responsible Plant Manager 5 s Autonomous Maintenance Planned Maintenance Individual Improvement Quality Maintenance arly quipment Management Safety Training People Development 18

19 PROMOTION STRUCTUR (OVRLAPPING SMALL GROUPS) PLANT MANAGR STAFF MANAGRS OPRATIONS TPM PILLARS & PROMOTION OFFIC DPARTMNT MANAGRS TPM PROMOTRS DPARTMNT SUPRVISORS TPM TAM 19

20 VISION STATMNT: TPM PLANT WID IMPLMNTATION Q

21 T.P.M. IMPLMNTATION ACTIVITIS MANAGR TAMS 21

22 PRPARATION / PLANNING STAG # DFIN PILOT LINS # AMOUNT OF MACHINS INCLUDD PR LIN # DFIN COR TAM MMBRS OF ACH LIN # SLCT TAM MMBRS PR MACHIN # START ACTIVITIS IN PILOT MACHINS (bottle neck.) 22

23 Line and Machine Selection Courtesy, in part, of Motorola SPS. B-820 Machine 1 Machine 2 N-661 POWR HATR Machine 3 Machine 4 B-609 V

24 TPM Implementation Plan ACTIVITIS Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 PRPARATION STAG I M P L M N T A T I O N S T A R T T A R G T DFIN STRATGIS MASTR PLAN ORGANIZATION INTRODUCTION TRAINING PUBLICITY MODL MACHINS Machine 1 Machine 2 Machine 3 Machine 4 XTND IMPLMNTATION SIMILAR PRODUCTION LINS COMPLT IMPLMNTATION DFIND ARAS 1 T P M K I C K O F F 2 3 AUTONOMOUS MAINTNANC & RDUC 6 BIG LOSSS XTND SIMILAR MACHINS 30% to 50% 100%

25 TPM 90 Days xplosion Plan PILLARS October November December ww40 ww41 ww42 ww43 ww44 ww45 ww46 ww47 ww48 ww49 ww50 ww51 ww52 Machine 1 PILOT TAM Step 3 Start Planned maintenance Start 6 big losses Start Individual Improvement Start 10 xtension teams step mc 3 mc 3 mc 19 xtension teams Start step 1 7 mc 6 mc 6 mc Machine 2 PILOT TAM Step 2-3 Start Planned maintenance Start 6 big losses Step 1 Step 2 Individual Improvement Step 1 11 xtension teams step 1-2 B mc 2 mc 2 mc B-601 L-604 Machine 3 PILOT TAM Step 2-3 Start Planned maintenance Start 6 big losses Start Individual Improvement Start 6 xtension teams step mc 4 mc 2 xtension teams Start step 1 Start Machine 4 PILOT TAM 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 IMPLMNTATION MODL GANTT TPM Activity Board xtension Teams Server Data collection M1 M2 M3 M4 GM Audit Team presentations TPM Office Audit Consultant visit TPM Meeting Local BOOT CAMP TPM MCO MTING, JAPAN Pillars meeting

26 T.P.M. TRANSITION CURV D N I A L POLICIS DVLOPMNT T.P.M. PROMOTION OFFIC START MANAGMNT MACHINS FOCUS IN FW QUIPMNT FOCUS TRAINING SUCCSS STORIS 5 S s KICK OFF CONSULTANT IN T.P.M. PROMOTION DLGATION INCLUD T.P.M. IN PRFORMANC MANAGMNT PLAN. INCLUD T.P.M. IN JOB DSCRIPTION. ACCLRATD DPLOYMNT. CONSULTANT OUT C O M M I T M N T DVLOP DATA COLLCTION SYSTM ATTNTION TO FOCUS TAMS TRAINING DPLOYMNT IMPLMNTATION PLAN RSOURC IMPLMNTATION R S I S T A N C X P L O R A T I O N GOALS STTING FOR ALL ORGANIZATION. LOOK FOR ADDITIONAL WAYS TO DPLOY T.P.M. FINISH CONFLICT WITH TH CULTUR ORGANIZATION ALIGNMNT RWARD SYSTM CONTROL CHAOS 26

27 KY GOALS Courtesy, in part, of Motorola SPS. 1.- TOTAL QUIPMNT FFCTIVNSS % 85 A) quipment Breakdown HOURS/MONTH 1/10 B) M.T.B.A. MINUTS 1x10x C) M.T.B.F. HOURS 1x2x 2.- RJCT CAUSD BY LIN QUIPMNT PPM 1/5 3.- LIN RJCT RAT % 1/5 4.- CYCL TIM DAYS 0.8X 5.- FATAL RROR AT CUSTOMR # OF ON TIM DLIVRD % MANUFACTURING COST USD 20% LSS 8.- LABOR PRODUCTIVITY K.UNITS /# OF D/L 2X 27

28 AUTONOMOUS MAINTNANC. MANUFACTURING SPCIALIST 28

29 AUTONOMOUS MAINTNANC IS: Maintenance performed by equipment operators. TH FIRST 3 STPS OF AUTONOMOUS MAINTNANC. STP # 1 INITIAL CLANING. STP # 2 COUNTRMASURS FOR TH CAUSS OF FORCD DTRIORATION AND IMPROVING HARD-TO-ACCSS ARAS. STP # 3 MAKING A TNTATIV CLANING/ LUBRICATION STANDARD. 29

30 AUTONOMOUS MAINTNANC Courtesy, in part, of Motorola SPS W s Major Problems Selection Formats: Daily Cleaning & Initial Inspection Hot Spots, CAP-DO Develop One Point lesson 6 3 Put F Tags Step # 1 Initial Cleaning Standardization Cleaning / Lubrication 7 Initial Cleaning (Inspection) 2 Photos Before Photos After Training in One Point Lesson

31 AUTONOMOUS MAINTNANC Courtesy, in part, of Motorola SPS. 5 4 Put F Tags Failures Analysis Why s Analysis Actions in Sources of Contamination & Hard access areas 6 3 Find & List Areas of Hard Access Step # 2 Sources of Contamination & Hard Access Areas Modify Covers For asy Visualization & Quick Disassemble 7 2 Find & List Sources of Contamination Initial Inspection Final Inspection (Audit) Remove F Tags

32 AUTONOMOUS MAINTNANC Courtesy, in part, of Motorola SPS. 5 4 Improve time of execution Verify actual time Vs estimated Detail activities 6 3 Step # 3 Put F Tags (stablish time & frequency) 3 Tentative Standards Remove F Tags 7 Cleaning / Lubrication implementation 2 2 Develop tentative standards Apply activities to similar machines

33 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 33

34 PLANT OVRVIW xpansion Plan TPM Self Assessment Asia Benchmarking TPM Implementation xpansion Plan 34

35 T.P.M. DPLOYMNT Courtesy, in part, of Motorola SPS. L I N F L O W CURRNT QUIPMNT IN T.P.M. SAM KIND OF QUIPMNT 1999/2000 XPANSION

36 PROJCTD PROGRSS IN TAMS Q-1 98 Line A.M. STP # 1 A.M. STP # 2 A.M. STP # 3 Wafer Process Line Line Line Line

37 T.P.M. FOLLOW-UP TAMS PRSNTATION TAMS AUDITS TAMS MTING Consultant X MANAGRS VISITS PRSNTATION 6 TAMS PR MONTH 6 TAMS PR MONTH WKLY TWO DAY VRY TWO MONTHS MONTHLY MTING 37

38 PLANT OVRVIW TPM Self Assessment Asia Benchmarking Pilot Team Case Study TPM Implementation xpansion Plan Pilot Team Case Study 38

39 PILOT MACHIN N

40 30 Defectives N N N JAN 96 FB JUN JUL MAR AUG APR SP MAY OCT 96 40

41 % T. C. DOWN TIM Courtesy, in part, of Motorola SPS. N % 20% N./96 17% 15% 10% 5% FB 18% MAR 20% ABR 12% MAY 15% JUN 23% JUL 20% AGO 18% SP 23% OCT./96 18% 0% 25% N./96 FB MAR ABR MAY JUN JUL AGO SP OCT./96 % T. C. 20% N % 10% 5% 12% 11% 10% 11% 8% 9% 7% 6% 8% 10% 0% 25,00% 20,00% N./96 FB MAR ABR MAY JUN JUL AGO % T. C. SP OCT./96 N ,00% 10,00% 5,00% 0,00% 7,50% 8% 4% 7% 9% 5% 3% 5% 6% 8% 41

42 CLANING IS INSPCTION... 5 S AUTONOMOUS MAINTNANC 42

43 INSPCTION IS DTCTION. CRASH Broken Part 43

44 PRSSUR Courtesy, in part, of Motorola SPS. CORRCT INCORRCT TO MUCH PRSSUR CORRCT ALIGNMNT INCORRCT GAUG NO 44

45 CORRCT CNTRING INCORRCT Dummy Part CORRCT SYMMTRY INCORRCT BNT 45

46 CONTACT CORRCT INCORRCT 46

47 TO STANDARDIZ AND PRVNT RCURRNC Courtesy, in part, of Motorola SPS. One Point Lesson 47

48 MACHIN PRFORMANC 48

49 25 23 Defectives Courtesy, in part, of Motorola SPS Sep-96 Oct Dec-96 Jan-97 6 Feb 3 Mar 1 Abr 2 May Jun Jul ZRO Defectives Ago Sep % D.T. 25% DOWN TIM P.C. BOARD DAMAGD 20% Oct-96 18% Nov-96 Dec-96 Jan-97 Feb Mar Apr 20% May Jun Jul Aug Sep 15% 15% 10% 5% 9% 8% 7% 5% 12% 6% 4% 3% 3% 0% 49

50 WHAT IS NXT? LINK 6 Big Losses 4 4 Autonomous Maintenance 3 Planned Maintenance 50

51 51

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