Toyota Production System (TPS) : Zero Defects Strategy Just-In-Time Strategy Zero Loss Strategy

Toyota Production System (TPS)
Zero Defects Just-In- Zero

Strategy Time Loss
Strategy Strategy
SPC Kanban TPM

6 Sigma SMED Low-cost
automation
FMEA One-piece
flow/Synchro
Poka-Yoke
U-shaped cells
DS-TC, zma Europa Manager Meeting 01.10.20 1

Origin of Synchro maintenance
1951 Introduction of Preventive Maintenance (PM)
1953 20 Japanese companies build a PM research team
1960 Development of a system for Preventive Maintenance
1969 Responsibility for maintenance transferred to production

personnel Total Productive Maintenance (TPM)
1991 Volvo Cars Europe (Belgium) is the first European company to

win the PM Excellent Plant Award
2003 ....................
DS-TC/Klaus Zimmermann, Manager Training und Consulting Europa Manager Meeting im September 2003 01.10.20 2
What is TPM?
“In TPM, the machine operator

is responsible for the maintenance of the
machine as well as it’s operation.”
Nakajima
…. this frees up technicians to

improve productivity
Objective of Total Productive Maintenance (TPM)
Maximize
Machine
Efficiency
TPM means:
Maintaining plant so that it is

as productive as possible
and has a long service life
TPM
MMachine Efficiency
Maximize
Kaizen – Continuous
Planned Maintenance
Improvement
Education and
Maintenance
Autonomous
Maintenance
Preventive
Training
5Ss translate to:
Housekeeping, Workplace organization, Cleanup, Cleanliness, Discipline
(Spic & Span Sorting Shifting Sustaining Sticking to it)
The 6 big losses in production
Breakdown Set-up and adjustment
Quality Speed
Starting velocity Idling and minor stoppage
The aims of Kaizen (Continuous Improvement)
• Zero breakdowns
• Zero defects
• Optimize the current condition of the
production line
• Responsibility: cross-functional teams
Reinigungsplan Bottrop
Reihe: 535/9 Meisterbereich/Abteilung: M 2
The aims of Autonomous Maintenance 2

Maschine
Verschließ-
Eigenschaften:
Staubfrei
Arbeitsweise:
absaugen
Hilfsmittel:
Staubsauger
Intervall:
wöchentlich
maschinen Lackabriebfrei abwischen Maschinen-
Stahl- und Kehren reiniger
• Employees increase their awareness of M-5268 Bod. Zinnfädenfrei
Schmierfettfrei
Putztuch
Besen
M-5267O'Bod.
responsibility for production lines and
• Develop sensitivity for everything that is
exceptional in and around the machine - täglich wird gefegt
- bei Maschinenstörungen wird geputzt
(production line)
1=Schweißmaschinen-Bediener/in 2=Falzmaschinen-Bediener/in
3=Palettierautomat-Bediener/in
Innenflächen der Schutzhauben

Hebelträger
Gesamte Maschine von Außen
Aufnahmen an den Sternen
• Responsibility: Manufacturing
The 7 steps of Autonomous Maintenance
Jan 03 Feb 03 Mrz 03 Apr 03 Mai 03 Jun 03 Jul 03 Aug 03 Sep 03 Okt 03 Nov 03 Dez 03
All-out Autonomous
Ziele TPM DRULA TPM TPM R 531 + TPM DRULA TPM TPM R 526 Wertstromde
Maintenance
Stufe 1 R535/539 Stanzerei Stufe 2 531+ 535/539 Stufe 2 sign Kanister
Stufe 2 Stufe 2 Stufe 3 Wickelanlage
Wertstrom Wertstrom
Wichtige
Anbindung Zuschnei-
Improve standards for

Termine
Welding derei Zentral
1 2
autonomous inspection
10.02.03 17.03.03 07.04.03
27.01.03
TPM TPM TPM
TPM DRULA
Stanzerei Stanzerei R535539
R54 Stufe 1
Audit Stufe 1 Stufe 2 Stufe 3
17.02.03 18.3.03 08.04.03
TPM R526 RWS TPM R531
Stufe 1 Stanzerei Stufe 2
18.02.03
Workshops /
TPM Stufe 2
Conduct autonomous
Planspiel
R535/539
inspection
Anzahl
Workshops
Prepare teams for

1 2 2 2
M itarbeiter-
schulung
HPS
FESTO
= HPS Workshops
= FESTO Workshops Mitarbeiterschulungen:
autonomous inspection
Anzahl WS Festo 3
Standards for cleaning

& inspection
Eliminating sources of
contamination
Initial cleaning
The aims of Periodic Maintenance
To develop effective an effective maintenance
regime – which means
• Improved, process-oriented maintenance with

• High flexibility by using a Maintenance
Planning System (MPS)
• Short response time
Responsibility: Maintenance
The aims of Education & Training
• Enhance the knowledge and skills of all
employees and technicians as a basis for
Continuous Improvement within the TPM
concept
• Training covers:
• TPM culture
• TPM basics
• TPM tools of
• Communication
• Responsibility: Production, maintenance

The aims of Preventive Maintenance
• Improve maintenance Prod ukt
• Improve the reliability of the process En twicklun
ri eb g
• Optimize machine operation et
An n twu
• Reduce start-up time
E
la g rf
e n-
Preventive
Ablauf
Maintenance
io n
n s t e n-
r uk t
Ko Anl ag
• Responsibility: Design/development
In
a ll
s
a ti
t
on u ng
He r s t ell
Maximize machine efficiency by minimizing machine losses
0% 100 %
Total available time
Operating time Downtime
Productive time Stoppages

Time loss due to
Planned downtime
Net operating time Yield
Time loss due to
Valuable time Defects Unplanned stoppages
Time loss due to
reduced machine yield
Time loss due to
defects and rework
Machine losses in detail
Total available time
Operating time Downtime
Stoppages Weekends
Productive time
Time loss due to Holidays
planned downtime No orders
Net operating time Yield
- Breakdowns
Time loss due to
Valuable time Defects unplanned stoppages - Setup &
adjustments
- Idle time & minor
Time loss due to stoppages
reduced machine yield - Reduced speed
Time loss due to - Quality problems

defects and rework - Rework Reduced starting
velocity
Overall Equipment Effectiveness (OEE)
OEE =
Availability x
Performance Rate x
Quality Rate
Calculation example:
Planned cycle time x Number of products processed x Rejects x Rework

Planned working time
TPM – Requirements and opportunities
First, we have to understand how the operator’s job and their system changes
in the culture of TPM!
Situation before introducing Autonomous Situation after introducing Autonomous

Maintenance Maintenance
Maintenance tasks Production tasks Production tasks Maintenance tasks
• Cleaning Cleaning • Cleaning Freed capacity

• Lubrication • Lubrication Can be used for:
• Maintenance • Maintenance • Preventive Maintenance
• Inspection • Inspection • Continuous Improvement
• On-site training of
• Repair Producing employees
• Preventive
Producing
Maintenance
Repair
Requirements and opportunities for Festo – End-user focus
What consequences does the new job have for operators?
Example: An operator has to call the right technician (electrician, mechanic)

in the event of a breakdown of, for example, a cylinder
This requires the operator to understand
• The function of a cylinder in the machine and
• The function of the cylinder itself
How can Festo support operators ?

• Single-point lessons
• Visual Management
• Checklist’s for failure analysis
• Low-cost intelligent solutions
Example of a single-point lesson: Cylinder ...
Hose for
extension
Single-point lesson:
Objective: The operator is able to
1 Retraction Single Point Lesson:
change a cylinder on site.
Objective: The operator is
Content:
able to …
Cylinder marking Function of theofcylinder
Function the Cylinderin the
in
the Machine:....................
machine:....................
2 1A1 Design/Function of the
Design/function of the cylinder
Cylinder itself:...................
Extension itself:...................
Steps of Assembly:...........
Assembly steps:...........
Safety Aspects:..............
SafetyCleaning
aspects:..............
Tips:...................
Extension: 2 depressurised Cleaning tips:...................
Maintenance Tips:............
1 pressurised
Retraction: 1 depressurised
Maintenance tips:............
Hose for
Retraction 2 pressurised
Example of Visual Management
Marking points for valves

Markings have to be big enough!
Control system shows that 4 or 2 is 2V1

pressurized
Information, for example: Date Technician Defect
How long has the valve been installed?
Example of Visual Management
Line XX Air unit 2.7
1 Pressure
0-6 bar
Air supply
Air outlet
MAX
Water
separator MIN Lubricator
2 3
Example of low-cost automation of order picking

Toyota Production System (TPS) : Zero Defects Strategy Just-In-Time Strategy Zero Loss Strategy

Uploaded by

Copyright:

Available Formats

Toyota Production System (TPS) : Zero Defects Strategy Just-In-Time Strategy Zero Loss Strategy

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Toyota Production System (TPS) : Zero Defects Strategy Just-In-Time Strategy Zero Loss Strategy

Uploaded by

Copyright:

Available Formats

Toyota Production System (TPS)

Zero Defects Just-In- Zero

SPC Kanban TPM

DS-TC, zma Europa Manager Meeting 01.10.20 1

1951 Introduction of Preventive Maintenance (PM)

1953 20 Japanese companies build a PM research team

1960 Development of a system for Preventive Maintenance

1969 Responsibility for maintenance transferred to production

1991 Volvo Cars Europe (Belgium) is the first European company to

“In TPM, the machine operator

…. this frees up technicians to

Maintaining plant so that it is

Breakdown Set-up and adjustment

Starting velocity Idling and minor stoppage

• Responsibility: cross-functional teams

Reihe: 535/9 Meisterbereich/Abteilung: M 2

The aims of Autonomous Maintenance 2

Innenflächen der Schutzhauben

Improve standards for

Prepare teams for

Standards for cleaning

• Improved, process-oriented maintenance with

• Responsibility: Production, maintenance

Productive time Stoppages

Total available time

Operating time Downtime

Time loss due to - Quality problems

Planned cycle time x Number of products processed x Rejects x Rework

Situation before introducing Autonomous Situation after introducing Autonomous

• Cleaning Cleaning • Cleaning Freed capacity

Example: An operator has to call the right technician (electrician, mechanic)

How can Festo support operators ?

Marking points for valves

Control system shows that 4 or 2 is 2V1

Information, for example: Date Technician Defect

How long has the valve been installed?

Line XX Air unit 2.7

You might also like