TPM

Courtesy, in part, of Motorola SPS.
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Welcome To
Cayman Systems USA 513 777-3394

1998 Revision A 980810
TPM Awareness Information

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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 DEVELOPMENT PROGRAM
Implementing Total Productive Maintenance
Seiichi Nakajima.


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WHAT IS T.P.M. ??
Definition of T.P.M :
T.P.M. IS: A PRODUCTIVE MANUFACTURING SYSTEM with the TOTAL
Participation of: Managers, Supervisors, Engineers,
Technicians and Operators.
T.P.M. Includes the Following Benefits:
Maximize Overall Equipment Effectiveness
Establishment a Complete System of Maintenance for the Machine Entire
Life
Create a Better Work Environment, Promoting the Participation for All
Employees


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T.P.M. = Medical Science of Equipment
PRODUCTION
Foton
AUTOMATION
B-820
VIDEO-AUTO DIE-BONDER MODEL 8030A
POWER
HEATER


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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
Early Equipment Management
Education/Training (People Development)
Safety


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PILLARS OF TPM
A
U
T
O
N
O
M
O
U
S
M
A
I
N
T
E
N
A
N
C
E
Q
U
A
L
I
T
Y
M
A
I
N
T
E
N
A
N
C
E
P
L
A
N
N
E
D
M
A
I
N
T
E
N
A
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C
E
I
N
D
I
V
I
D
U
A
L
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M
P
R
O
V
E
M
E
N
T
T
R
A
I
N
I
N
G
P
E
O
P
L
E
D
E
V
E
L
O
P
S
A
F
E
T
Y
E
H
S
E
A
R
L
Y
E
Q
U
I
P
M
A
N
A
G
E
M
E
N
T
5Ss


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T.P.M.
Total Productive Manufacturing
People , Equipment and Product
Improvement by Working Together.
EXCELLENCE


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PLANT
OVERVIEW
PLANT
OVERVIEW


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TPM
Self Assessment
PLANT
OVERVIEW
TPM
Self Assessment


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TPM Self Assessment

Background:
1991 First attempt to implement TPM.
TPM consultant provides training to selected Managers,
Supervisors and Engineers.

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

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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.
Equipment conditions analysis performed.
Most of the teams cover the initial cleaning.
Activities are focused on six big losses detected and 5 Ss
implementation.

11

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Asia
Benchmarking
PLANT
OVERVIEW
TPM
Self Assessment
Asia
Benchmarking

12

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TPM Benchmarking
Asia Facilities
Facility 1
Facility 2
Facility 3
Committee:
Objective:

1996
April
May
June
4 Chosen Folks
Learn from Asia success experiences in TPM
implementation and come up with directions for
Plant implementation.
13

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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 ).
Each 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

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PLANT
OVERVIEW
TPM
Implementation
TPM
Self Assessment
Asia
Benchmarking
TPM
Implementation

15

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IMPLEMENTATION/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

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T.P.M. POLICY
# ESTABLISH AN INTEGRATED STRUCTURE TO PROMOTE T.P.M.
AS A COMPANY CULTURE.
# MAXIMIZE OVERALL EQUIPMENT EFFECTIVENESS
# TOTAL EMPLOYEE INVOLVEMENT.
# CULTIVATE EQUIPMENT & PROCESS RELATED EXPERTISE THROUGHOUT
SHOP FLOOR. ( Autonomous Maintenance, Planned Maintenance etc..)
# ESTABLISH A RELIABILITY AND MAINTAINABILITY SYSTEM TO MAXIMIZE
EQUIPMENT LIFE TIME. (Planned Maintenance Autonomous Maintenance,
Individual Improvement, Early Equipment Management.)
# ALL EMPLOYEES MUST PARTICIPATE IN T.P.M TRAINING PROGRAM.
# ALL AREAS MUST FOLLOW T.P.M. ESTABLISHED GUIDE LINES.
# DEPARTMENT HEAD IS RESPONSIBLE TO ACCOMPLISH AND SUPPORT
T.P.M. GOALS.
17

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T.P.M. PLANT WIDE STRUCTURE

TPM
Responsible
Plant Manager
T.P.M. Office
5 s
Quality
Maintenance

Autonomous
Maintenance
Early
Equipment
Management
Planned
Maintenance
Safety
Individual
Improvement
Training
People
Development
18

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PROMOTION STRUCTURE
(OVERLAPPING SMALL GROUPS)
PLANT
MANAGER
STAFF MANAGERS
OPERATIONS
TPM PILLARS
& PROMOTION
OFFICE
DEPARTMENT
MANAGERS
DEPARTMENT
SUPERVISORS
TPM
PROMOTERS
TPM TEAM

19

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VISION STATEMENT:
TPM
PLANT WIDE
IMPLEMENTATION
Q1 2000

20

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T.P.M. IMPLEMENTATION ACTIVITIES

MANAGER TEAMS

21

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PREPARATION / PLANNING STAGE

# DEFINE PILOT LINES
# AMOUNT OF MACHINES INCLUDED PER LINE
# DEFINE CORE TEAM MEMBERS OF EACH LINE
# SELECT TEAM MEMBERS PER MACHINE
# START ACTIVITIES IN PILOT MACHINES (bottle neck.)

22

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Line and Machine Selection
B-820
B-820
Machine 1
Machine 2
N-661
POWER
HEATER
Machine 3
Machine 4
B-609
B-609
V-701
V-701

23
TPM Implementation Plan

ACTIVITIES
DEFINE STRATEGIES
MASTER PLAN
PREPARATION
ORGANIZATION
STAGE
INTRODUCTION TRAINING
PUBLICITY
I
M
P
L
E
M
E
N
T
A
T
I
O
N
S
T
A
R
T
T
A
R
G
E
T
MODEL MACHINES
Machine 1
Machine 2
Machine 3
Machine 4
EXTEND
IMPLEMENTATION
SIMILAR
PRODUCTION LINES
COMPLETE
IMPLEMENTATION
DEFINED AREAS
1996
1997
1998
1999
Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2
T
P
M
K
I
C
K
O
F
F
2000
Q3 Q4 Q1 Q2
AUTONOMOUS MAINTENANCE
&
REDUCE 6 BIG LOSSES
EXTEND SIMILAR MACHINES
30%
to
50%
100%
TPM 90 Days Explosion Plan

October
November
December
ww40 ww41 ww42 ww43 ww44 ww45 ww46 ww47 ww48 ww49 ww50 ww51 ww52
Machine 1
PILOT TEAM
PILLARS
Step 3
Planned maintenance
6 big losses
10 Extension teams
step 1-2
19 Extension teams
Start step 1
Machine 2
PILOT TEAM
Step 2-3
Planned maintenance
6 big losses
11 Extension teams
step 1-2
Machine 3
PILOT TEAM
Step 2-3
Planned maintenance
6 big losses
6 Extension teams
step 1-2
2 Extension teams
Start step 1
Machine 4
PILOT TEAM
Step 1-2
Planned maintenance
6 big losses
4 extension teams
Start step 1
IMPLEMENTATION MODEL
GANTT
TPM Activity Board Extension Teams
Server
Data collection
GM Audit
Team presentations
TPM Office Audit
Consultant visit
TPM Meeting
Local BOOT CAMP
TPM MCOE MEETING, JAPAN
Pillars meeting
Start
Start
Start
Start
4 mc
7 mc
3 mc
6 mc
3 mc
6 mc
Start
Start
Step 1
Step 2
B-613
3 mc
Step 1
2 mc 2 mc
B-601
L-604
Start
Start
Start
Start
2 mc
Start
4 mc
Start
Start
Start
Start
a-820 a-821 J-701 J-601
M1
M2
M3
M4

Thank You!
T.P.M. TRANSITION CURVE
D
E
N
I
A
L
POLICIES DEVELOPMENT
T.P.M. PROMOTION OFFICE START
MANAGEMENT MACHINES
FOCUS IN FEW EQUIPMENT
FOCUS TRAINING
SUCCESS STORIES
5 Ss
T.P.M. PROMOTION DELEGATION

INCLUDE T.P.M. IN PERFORMANCE
MANAGEMENT PLAN.
INCLUDE T.P.M. IN JOB
DESCRIPTION.
ACCELERATED
DEPLOYMENT.
CONSULTANT
IN
CONSULTANT
OUT
KICK OFF
DEVELOP DATA COLLECTION SYSTEM

ATTENTION TO FOCUS TEAMS
TRAINING DEPLOYMENT
IMPLEMENTATION PLAN
RESOURCE IMPLEMENTATION

R
E
S
I
S
T
A
N
C
E
E
X
P
L
O
R
A
T
I
O
N
C
O
M
M
I
T
M
E
N
T
GOALS SETTING FOR

ALL ORGANIZATION.
LOOK FOR ADDITIONAL WAYS
TO DEPLOY T.P.M.
FINISH CONFLICT WITH THE CULTURE
ORGANIZATION ALIGNMENT
REWARD SYSTEM
CONTROL CHAOS
26

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KEY GOALS
1.- TOTAL EQUIPMENT EFFECTIVENESS
A) Equipment Breakdown
B) M.T.B.A.
C) M.T.B.F.
%
HOURS/MONTH
MINUTES
HOURS
85
1/10
1x10x
1x2x
2.- REJECT CAUSED BY LINE EQUIPMENT
PPM
1/5
1/5
3.- LINE REJECT RATE

4.- CYCLE TIME
DAYS
0.8X
5.- FATAL ERROR AT CUSTOMER
# OF
6.- ON TIME DELIVERED
98
7.- MANUFACTURING COST
USD
20% LESS
8.- LABOR PRODUCTIVITY
K.UNITS /# OF D/L
2X

27

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AUTONOMOUS MAINTENANCE.
MANUFACTURING SPECIALIST

28

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AUTONOMOUS MAINTENANCE IS:

Maintenance performed by equipment operators.
THE FIRST 3 STEPS OF
AUTONOMOUS MAINTENANCE.
STEP # 1 INITIAL CLEANING.
STEP # 2 COUNTERMEASURES FOR THE CAUSES

OF FORCED DETERIORATION AND IMPROVING
HARD-TO-ACCESS AREAS.
STEP # 3 MAKING A TENTATIVE CLEANING/
LUBRICATION STANDARD.
29

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AUTONOMOUS
MAINTENANCE
5
Formats:
6
Daily Cleaning &
Initial
Inspection
4
Hot Spots, CAP-DO
5Ws
Develop One
Point lesson
Major Problems
Selection
Step # 1
3
Put F Tags
Initial Cleaning
Standardization
Cleaning /
Lubrication
Training in
One Point Lesson
Initial Cleaning
(Inspection)
8
2
Photos Before
Photos After

30

Thank You!
AUTONOMOUS
MAINTENANCE
5
Failures Analysis
Whys Analysis
4
Put F Tags
Actions in
Sources of
Contamination &
Hard access areas
Step # 2
3
Find & List

Areas of Hard
Access
Sources of
Contamination &
Hard Access Areas
Find & List

Sources of
Contamination
Modify Covers For

Easy Visualization
& Quick
Disassemble
Remove F Tags
Initial Inspection
Final Inspection
(Audit)

31

Thank You!
AUTONOMOUS
MAINTENANCE
5
Improve time of
execution
Verify
actual time
Vs estimated
Put F Tags
(Establish time
& frequency)
3
Detail
activities
Step # 3
Tentative
Standards
Cleaning / Lubrication
implementation
2
Remove
F Tags
Apply activities to
similar machines
Develop tentative
standards

32

Thank You!
TPM Teams Status

October 1997
Number of Hot Spots detected:

Number of Hot Spots solved:
One Point Lesson developed:
One Point Lesson Taught:
Number of teams on TPM:
Teams on step 3:
Teams on step 2:
Teams on step 1:
284
126
44
34
27
1
2
24
33

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PLANT
OVERVIEW
Expansion Plan
TPM
Self Assessment
Asia
Benchmarking
TPM
Implementation
Expansion Plan

34

Thank You!
T.P.M. DEPLOYMENT
L
I
N
E
F
L
O
W
CURRENT EQUIPMENT IN T.P.M.

SAME KIND OF EQUIPMENT
1
9
9
8
1997
1999/2000 EXPANSION
35

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PROJECTED PROGRESS IN TEAMS

Line
Wafer Process
Line 1
Q-1 98
A.M. STEP # 1 A.M. STEP # 2 A.M. STEP # 3

11
16
03
Line 2
03
11
01
Line 3
03
08
01
Line 4
04
01
01

36

Thank You!
T.P.M. FOLLOW-UP
TEAMS
PRESENTATION
TEAMS
AUDITS
TEAMS
MEETING
6 TEAMS
6 TEAMS
WEEKLY
PER
PER
MONTH
MONTH

Consultant X MANAGERS
VISITS
PRESENTATION
TWO DAY
EVERY
TWO
MONTHS
MONTHLY
MEETING
37

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PLANT
OVERVIEW
TPM
Self Assessment
Asia
Benchmarking
Pilot Team
Case Study
TPM
Implementation
Expansion Plan
Pilot Team
Case Study

38

Thank You!
PILOT MACHINE
N-62361

39

Thank You!
Defectives
30
25
20
25
23
23
22
20
20
21
18
19
17
15
10
7
5
8
6
8
6
6
3
7
5
0
N-662361
JAN 96
JUN

FEB
JUL
N-61162
MAR
AUG
N-634766
APR
SEP
MAY
OCT 96
40
% T. C.

Thank You!
SEP
AGO
JUL
JUN
MAY
ABR
MAR
18%
17%
23%
20%
18%
18%
15%
15%
N-662361
23%
20%
OCT./96
20%
FEB
25%
ENE./96
DOWN TIME
12%
10%
5%
OCT./96
SEP
AGO
JUL
JUN
MAY
ABR
MAR
ENE./96
25%
FEB
% T. C.
0%
20%
N-663242
15%
12%
10%
11%
10%
11%
8%
10%
9%
7%
5%
8%
6%
OCT./96
SEP
AGO
JUL
JUN
MAY
ABR
MAR
ENE./96
25,00%
FEB
% T. C.
0%
20,00%
15,00%
N-649666
10,00%
7,50%
5,00%
9%
8%
8%
7%
4%
5%
5%
6%
3%
0,00%

41

Thank You!
CLEANING IS INSPECTION....
5S
AUTONOMOUS
MAINTENANCE

42

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INSPECTION IS DETECTION.
CRASH
Broken Part

43

Thank You!
PRESSURE
CORRECT
INCORRECT
TO
TO MUCH
MUCH
PRESSURE
PRESSURE
CORRECT
ALIGNMENT
INCORRECT
GAUGE

NO
44

Thank You!
CORRECT
CENTERING
INCORRECT
Dummy Part
CORRECT
SYMMETRY
INCORRECT
BENT
BENT

45

Thank You!
CONTACT
CORRECT

INCORRECT
46

Thank You!
TO STANDARDIZE AND
PREVENT RECURRENCE
One Point Lesson

47

Thank You!
MACHINE
PERFORMANCE

48

Thank You!
Defectives
25
23
20
18
ZERO
15
May
Jun
Jul
Ago
Sep
Abr
Mar
Feb
Jan-97
Dec-96
Oct-96
Sep-96
10
Defectives
10
3
1
P.C. BOARD
DAMAGED
% D.T.
DOWN TIME
15%
Sep
Aug
Jul
Jun
20%
May
Apr
Mar
Feb
Jan-97
Dec-96
18%
Nov-96
20%
Oct-96
25%
15%
12%
10%
5%
9%
8%
7%
5%
6%
4%
3%
3%
0%

49

Thank You!
WHAT IS NEXT?
6 Big
Losses
LINK
Autonomous
Maintenance

Planned
Maintenance
50

Thank You!

51

TPM

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Courtesy, in part, of Motorola SPS.

Cayman Systems USA 513 777-3394

TPM Awareness Information

Courtesy, in part, of Motorola SPS.

Cayman Systems USA 513 777-3394

TPM Awareness Information

Courtesy, in part, of Motorola SPS.

Cayman Systems USA 513 777-3394

TPM Awareness Information

Courtesy, in part, of Motorola SPS.

T.P.M. = Medical Science of Equipment

VIDEO-AUTO DIE-BONDER MODEL 8030A

Cayman Systems USA 513 777-3394

TPM Awareness Information

Courtesy, in part, of Motorola SPS.

The Main objective of TPM is :

Cayman Systems USA 513 777-3394

TPM Awareness Information

Courtesy, in part, of Motorola SPS.

Cayman Systems USA 513 777-3394

TPM Awareness Information

Courtesy, in part, of Motorola SPS.

Cayman Systems USA 513 777-3394

TPM Awareness Information

Courtesy, in part, of Motorola SPS.

Cayman Systems USA 513 777-3394

TPM Awareness Information

Courtesy, in part, of Motorola SPS.

Cayman Systems USA 513 777-3394

TPM Awareness Information

Courtesy, in part, of Motorola SPS.

TPM Self Assessment

1991 First attempt to implement TPM.

TPM consultant provides training to selected Managers,

Supervisors and Engineers.

Lack of support and involvement results on failing the

TPM Awareness Information

Courtesy, in part, of Motorola SPS.

TPM Self Assessment

One Staff Mgr. is assigned to lead the TPM Implementation

Cayman Systems USA 513 777-3394

TPM Awareness Information

Courtesy, in part, of Motorola SPS.

Cayman Systems USA 513 777-3394

TPM Awareness Information

Courtesy, in part, of Motorola SPS.

Cayman Systems USA 513 777-3394

TPM Awareness Information

Courtesy, in part, of Motorola SPS.

T.P.M. Manager (dedicated).

Cayman Systems USA 513 777-3394

TPM Awareness Information

Courtesy, in part, of Motorola SPS.

Cayman Systems USA 513 777-3394

TPM Awareness Information

Courtesy, in part, of Motorola SPS.

* Q3 1996, Consultant X is selected to be Consultant.

Cayman Systems USA 513 777-3394

TPM Awareness Information

Courtesy, in part, of Motorola SPS.

TPM Awareness Information

Courtesy, in part, of Motorola SPS.

T.P.M. PLANT WIDE STRUCTURE

Cayman Systems USA 513 777-3394