EXP_Wk3_TPM_06-10

Applying Six Sigma to TPM
Y (Maintenance Costs) = f (x1 , x2 , …. xn )
Roots of Maintenance Expense*
Design & Engr Nonpreventable 31% 17% Maintenance 8% Construction 5% Operations Management 7% 32%
Lunch, Breaks Holidays, Weekends Excess Capacity
net AVAILABLE OPERATING TIME
net PERFORMANCE RATE
(using available operating time)
net First Pass YIELD RATE
• Robust design of equipment for application duty • Equipment is installed for ease and consistency of operating and maintaining • Equipment is specified using standards
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Why is TPM Important?
1. TPM enables Stable Operations:
• Equipment Availability – Uptime
− Longer MTBF and shorter MTTR
• Productivity – Performance Rate
Moore, R., Pardue, E., Pride, A., Wilson,J. Reliability Based Maintenance—A vision for Improving Industrial Industrial Productivity, Computational Systems, Inc. Industry Report, Knoxville, TN
OEE is the characterization of Manufacturing Productivity
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HONEYWELL - CONFIDENTIAL
Turning TPM into Dollars
Availability
Machine downtime (hrs) x shop rate($/hr) = $ Lost Set-up/adjustment time (hrs) x shop rate ($/hr) = $ Lost
Total Productive Maintenance
Six Sigma Expert
EXP_Wk4_TPM_06-10
TPM Exercise
You have already read the Delphi article Build Your “House” of Production on a Stable Foundation. In your Table Groups, Teach Back to the class the following: 1. 2. 3. 4. 5. 6. How did Delphi find a cure to the downtime epidemic? What were the key elements of Delphi’s Machine Kaizen Events? How did TPM become critical in supporting the Kaizen Events? What additional Kaizen events were implemented and why? How did Delphi deal with cultural issues? What have been the results of Delphi’s Lean deployment?
(using available time & performance rate)
Quality Losses
OEE focuses on the specific Asset Level
100% OEE
(Entitlement)
% OEE
Benchmark: 80-90%
OEE = %Availability X %Performance Rate X %Yield Rate OEE = 85% X 97% X 93% = 76.7%
Typical Maintenance Practices Benchmark Maintenance Practices
Reactive Maintenance is very, very costly: 3 to 6 times the cost of Planned Maintenance!
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Remember – If any one factor is not at optimum, then it is costing us money $$$ !!!!!
TPM has a huge impact !!
*Raymond J. Oliverson, “Preventable Maintenance Costs More Than Suspected,” Maintenance Technology, September 1997
We must design, operate, & maintain our assets ‘right’ to control costs
Low cost producer for our customers & stockholders
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Why is TPM Important?
3. TPM reduces the risk of Health, Safety, and Environmental exposure through...
− Ensures designed rate of equipment is sustained
• First Pass Yield - Quality
− Fewer downtime events = improved quality & less waste − Steady state is always better than “up & down”
Performance EFra bibliotekficiency
(Reduced speed/Machine Design speed) x Machine run time x shop rate = $ Lost
Quality
COPQ expressed in dollars for scrap rework caused by machine maintenance issues = $ Lost
OEE=Availability x Performance Efficiency x Quality Rate
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Overall Equipment Effectiveness (OEE)
Total available TIME SCHEDULED (can be 24 x 365) Down Time Losses Speed Losses Scheduled Losses by Management Decision
Site becomes a predictable & reliable supplier for our customers
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HONEYWELL - CONFIDENTIAL
Why is TPM Important?
2. TPM promotes optimum life cycle costs:
− Standard materials of construction − Standard base of suppliers … which enables consistency − Standard design criteria (maintenance and operator access) − Standard spare parts
Lower risk for our employees & community
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Analysis of Maintenance Practices
60% 50% 40% 30% 20% 10% 0%
Reactive Preventive Predictive Proactive
Idling & minor stoppages
Reduced speed Defects in process Reduced yield
Productivity Performance Rate
Overall Equipment Effectiveness
First Pass Yield Quality
• x1 − − −
Reliability
Design (DFSS) Operations Maintenance
• x2 Process Effectiveness
− Planning & Scheduling − Preventive & Predictive − − − − −
Maintenance Skills Development Standards, parts & procedures Stores management Equipment Preparation & Work Permitting Contractor Management