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  • Kaizen and TPM - Case

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    MTBF improved over 8 times during 4 years period! Improvements Mean Time Between Failures (MTBF) 114 hours (2002) up to 915 hours (2006) Mean stops per machine per month 1,5 stop (2005) down to 0,8 stop (2006) Costs neutral (6,6% of sales)

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    MTBF improved over 8 times during 4 years period! Improvements Mean Time Between Failures (MTBF) 114 hours (2002) up to 915 hours (2006) Mean stops per machine per month 1,5 stop (2005) down to 0,8 stop (2006) Costs neutral (6,6% of sales)

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    37 visualizzazioni15 pagine

    Kaizen and TPM - Case

    Caricato da

    arrjud
    MTBF improved over 8 times during 4 years period! Improvements Mean Time Between Failures (MTBF) 114 hours (2002) up to 915 hours (2006) Mean stops per machine per month 1,5 stop (2005) down to 0,8 stop (2006) Costs neutral (6,6% of sales)

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    di 15

    TPM 2006

    By Peter Tijssen
    April 2007

    SMP Product overview

    Spherical Roller Bearing Cages

    Automotive Special Parts Taper Roller Bearing Cages

    SMP Production
    Veenendaal Lay out
    Roller dept.

    Stamping department of SMP Expedition

    SMP Dept.

    Driving Force team SMP

    Peter Tijssen- Bart van Genderen - Joris van Kasteren - Jan Hoogendoorn

    Activity examples of 2006


    Steel blaster IWK Stamping Fibro polishing Product Washing Machine Shadow boards Maintenance on shop floor Central Scrap Transport

    Transport belt eliminated

    Steel blaster

    New situation

    Old situation
    Old situation

    Advantages Less product damage Less maintenance Less space Less reclamations Less dropouts
    Transformation New situation

    IWK Stamping

    5-S on Local toolbox

    TPM Kaizen on IWK


    Old situation
    New situation Clear gauges & indicators

    Advantages: Break down reduction Easy to maintain Product quality improved

    Cover plate mounted

    Oil pollution prevent & Oil spillage prevent

    Fibro polishing

    New situation

    Advantages Replace machine in order to Optimize product flow Environmental improvement Reduced maintenance

    Product Washing Machine


    Replace isolation and painting complete machine

    Marking TPM spots incl gauges

    5-S activity
    Lubrication point Kaizen team

    Complete overhaul in 2 day kaizen event!

    Shadow boards

    Advantages All used tools close to workplace Easy to find, easy to store

    Maintenance on Shop floor


    Advantages: Small maintenance workshop in the middle of production floor. 5-S proofed Improved response time

    Old situation

    Construction of the workshop

    Result

    Central Scrap Transport

    New situation

    Advantages Break down reduction of belt Less cleaning time Improved MTBF stamping Saver work area
    New situation

    Results..
    MTBF PSD 2006 2000
    bedrijfsuren

    1500 1000 500 0

    2002 2003 2004 2005

    jan

    feb

    mrt

    apr mei maand

    jun

    jul

    aug sep

    okt

    nov dec

    ytd Doel

    PSD 114 137 168 792

    1050 367 1400 462 620 528 456 798 1560 1456 1456 821 915 832

    MTBF improved over 8 times during 4 years period !

    Improvements
    Mean Time Between Failures (MTBF) 114 hours (2002) up to 915 hours (2006) Mean stops per machine per month 1,5 stop (2005) down to 0,8 stop (2006) Mean unplanned repair hours per machine: 4,6 hours (2005) down to 2,3 hours (2006) Costs neutral (6,6% of sales)

    QUESTIONS?

    THANKS

    4 YOUR ATTENTION

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