Total Productive Maintenance (TPM) Practical Process Improvement

Transcription

1 Total Productive Maintenance (TPM) Practical Process Improvement

2 TPM blitz Kaizen Workshop Purpose: The purpose of this Kaizen Blitz is to improve the ability to respond to customer s demand through improved asset utilization, workplace organization and visual management. Objectives: 1. Complete Phase 1 & 2 TPM improvement activity 2. Improve OEE by 25% with 2 months 3. Improve Workplace Organization and Visual Management 2

3 TPM Definition TPM is a process that maximizes the productivity of equipment for its entire life. TPM fosters an environment where improvement efforts in Safety, Quality, Cost, Delivery and Creativity, are encouraged, through the participation of employees. Total Productive Maintenance Total means = ALL Employees 3

4 Agenda Day 1: Classroom training Phase 1 & 2, facility measurements & evaluations. Day 2: Classroom training Phase 3 & 4, maintenance measurements & evaluations, for better maintenance work flow. Day 3: Focused cleaning, sorting, inspection, modifications and/or laying out areas, for better maintenance work flow. Day 4: Improve safety, calibration, data collection, & lubrication in facility and maintenance areas. Evaluate and measure. 4 Day 5: Plan long term improvements. Team to present successes and action items.

5 Current State 1. Stabilize Failure Intervals 2. Improve Equipment Productivity 3. Maintenance Excellence 4. Predict Equipment Life Average Was Now Ratings: 5 0 = No obvious application of standard 1 = Some evidence of application of standard 2 = Fully applied standard

6 6 Current State

7 Current State Equipment Condition Fluid lines & fittings leak Grease fittings are dry & not covered Air filters are not present Pump motors are coated with dirt / contamination Electrical cabinet fans are coated with dirt/dust Gauges are not usable, dirty and not labeled Electrical connections are loose & wires are damaged Chemicals migrate causing contamination Fasteners are corroded / stripped Guards / shields are loose or missing Excessive solid / liquid waste is underneath Routine inspection difficult due to accessibility No ownership by employees EHS issues 7

8 Top 5 Failures (Based on Team experience) Defect % Solution 1 2 Degaste Bomba/ Friction in the pump 35% Prevent media from entering pump Poleas & Bandas/Pulleys & belts 20% Inspect/replace based on run time 3 Sello Mechanico en Molino/Seal on the Mill 5% Ensure ample supply of cold water from chiller 4 Fugas de tanque/leakage from tank 5% Fix/replace pipes 5 Operadore no disponable / Operator not available 35% Create checklist/walk pattern/inspection points 8

9 9 Team in Action

10 Team Azub Date: 11/11/2005 Page: of: 10 Item No. Description of Problem Counter Measure s actions Excessive sludge, water, trash, rusty metal, dust Paint is peeling, stained Slurry overflows from the Mill Clean entire plant/limpiar todo la planta Paint affected parts/pintar partas necessarias Repair float sensor/instalar sensor descarda Molina Person Responsible Gages air, water, temperature are unreadable Replace all affected gages Jose Martin 5 Leaking pipe under slurry tank Replace and re-seal pipes Edder Marlon Install signage(rotation, flow direction, equipment name, 6 No visual management indicators warnings) Jose Martin 78 OEE actions Agitator motors are clogged with dust which causes overheating and motor failure Clean and install filters Jorge Garcia 8 Slurry leaks from Mill pump housing 9 10 No indication of maintenance points (lube, fill, check, tighten) Media enters the mill pump and causes premature wear on internal pump parts 11 Critical parts are not always available Improper water temp causes seal failure on Mill Limited visibility to RPM controller (hidden in cabinet) EHS actions Change Mill pump & rebuild old pump Due Date % Complete Date Complete TEAM, OPERATORS TEAM, OPERATORS Santiago Lopez 11/11 11/11 25% Gilberto Vazquez Number and list points to service Jose Martin Repair/ replace mesh in Mill and inspect between batches for damage Andres Medina Create list and purchase as required Juan Cuestas Clean chiller and install air filters Re-mount controller on face of cabinet Jose Tolentino Andres Medina Access to pulleys/belts on agitator is poor(employee can fall) Install metal ladder/platform Contractor 16 Gate on landing over the Agitator is missing Replace the gate Gilberto Vazquez 17 Guards missing multiple places Clean/replace/repair guards TEAM, OPERATORS Agitator loading hatch causes excessive Add a chute that will support the 18 material spills bag of material Contractor 19 Sustain actions Gages, switches, sensors, filters etc do not get regular attention Preventatitve maintenance is limited due to 20 available evaluation tools Routine maintnence is not scheduled or 21 performed consistently 22 No weekly 5s review 23 No defined strategy for TPM deployment 24 No historical OEE data available Inspect/repair/clean gages, sensors, floats, limit switches, filters weekly Create Tool list for Preventative TPM (include thermography and ultra-sonic equipment Create and display schedule with weekly audit by leadership Operators 11/11 11/11 12/1 11/11 11/11 11/11 12/1 Raul Hernadez 11/21 Jose Martin 11/21 Weekly 5s review performed and reviewed by leadership team Dimitri Makres Leadership team to particpate in TBD TPM 2-day strategy design/planning session (See Dimitri Makres Begin tracking daily uptime/downtime and reasons Raul Hernadez Start 11/21 25% 25% 25% 25% 25% 25% 25% 25% 25%

11 Improvements Leaking pipes New pipe connections One thread holding the joint together!! 11 Contaminated Motor Cleaned & filter installed

12 Improvements Dirty water chiller Cleaned & filters installed 12 Non-working Gages Gages replaced

13 Improvements Need a ladder to grease Fittings accessible without ladder 13 Can you see the filter? Now you can

14 Improvements Difficult accessibility to belts/pm Ladder installed Guard removed 14 Solid waste under pump New Pump installed w/ guard

15 Improvements RPM control in cabinet RPM control accessible Open door Control visible with door closed 15 Dirty rags and trash Cleaned area

16 Improvements Messy load area Chute Angled Feed Chute 16 Missing safety railing Repaired safety railing

17 TPM Focused Improvement Objectives - Results Equipment: Acme Plant Date: week 11/7 Start Target 1st Day 2nd Day 3rd Day 4th Day 5th Day Post Event %Increase /Decrease Space (sq. ft.) Parts volume per day Walking distance (ft.) Parts travel distance (ft.) Throughput time Process cycle time Mistake Proofing Changeover (Total # ) Changeover (Total time) Exhaust air flow (CFM) Noise level (db) Scrap/year(concentrate) Visual controls EHS issues O.E.E. (%) ** 5 S rating 4-phase development score 3000 lbs % 61% Avg.11 Note: 1425 lbs concentrate ($2591) removed with this effort Avg.25 Avg % 20% 3.4 ** Estimated OEE based on experiential data 17

18 Learnings: 1) Keep area clean allows us to see problems before they occur 2) Employees area critical to TPM success 3) Start a new culture of owning the process 4) Safety cannot be overlooked Benefits: 1) Reduce/eliminate scrap to save estimated $ 5,400/year 2) Problems can be observed more quickly 3) Operators safety is increased 4) Process reliability improved 20% 18

19 Next Steps - Complete open items from Newsletter - Management Gemba walks to sustain changes - Management training on TPM basics - 5S blitz on the maintenance area/warehouse (5s score is 1.67) -TPM program design and deployment strategy (ref. Phase 3 Maintenance Excellence / Phase 4 Predictive Maintenance 19