Toyota Production System (TPS) : Zero Defects Strategy Just-In-Time Strategy Zero Loss Strategy
Toyota Production System (TPS) : Zero Defects Strategy Just-In-Time Strategy Zero Loss Strategy
Toyota Production System (TPS) : Zero Defects Strategy Just-In-Time Strategy Zero Loss Strategy
2003 ....................
DS-TC/Klaus Zimmermann, Manager Training und Consulting Europa Manager Meeting im September 2003 01.10.20 2
What is TPM?
DS-TC/Klaus Zimmermann, Manager Training und Consulting Europa Manager Meeting im September 2003 01.10.20 3
Objective of Total Productive Maintenance (TPM)
Maximize
Machine
Efficiency
TPM means:
DS-TC/Klaus Zimmermann, Manager Training und Consulting Europa Manager Meeting im September 2003 01.10.20 4
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)
DS-TC/Klaus Zimmermann, Manager Training und Consulting Europa Manager Meeting im September 2003 01.10.20 5
The 6 big losses in production
Quality Speed
DS-TC/Klaus Zimmermann, Manager Training und Consulting Europa Manager Meeting im September 2003 01.10.20 6
The aims of Kaizen (Continuous Improvement)
• Zero breakdowns
• Zero defects
• Optimize the current condition of the
production line
DS-TC/Klaus Zimmermann, Manager Training und Consulting Europa Manager Meeting im September 2003 01.10.20 7
Reinigungsplan Bottrop
(production line)
1=Schweißmaschinen-Bediener/in 2=Falzmaschinen-Bediener/in
3=Palettierautomat-Bediener/in
• Responsibility: Manufacturing
DS-TC/Klaus Zimmermann, Manager Training und Consulting Europa Manager Meeting im September 2003 01.10.20 8
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-
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
HPS
FESTO
= HPS Workshops
= FESTO Workshops Mitarbeiterschulungen:
autonomous inspection
Anzahl WS Festo 3
Eliminating sources of
contamination
Initial cleaning
DS-TC/Klaus Zimmermann, Manager Training und Consulting Europa Manager Meeting im September 2003 01.10.20 9
The aims of Periodic Maintenance
To develop effective an effective maintenance
regime – which means
Responsibility: Maintenance
DS-TC/Klaus Zimmermann, Manager Training und Consulting Europa Manager Meeting im September 2003 01.10.20 10
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
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
DS-TC/Klaus Zimmermann, Manager Training und Consulting Europa Manager Meeting im September 2003 01.10.20 12
Maximize machine efficiency by minimizing machine losses
0% 100 %
Total available time
Operating time Downtime
DS-TC/Klaus Zimmermann, Manager Training und Consulting Europa Manager Meeting im September 2003 01.10.20 13
Machine losses in detail
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
OEE =
Availability x
Performance Rate x
Quality Rate
Calculation example:
DS-TC/Klaus Zimmermann, Manager Training und Consulting Europa Manager Meeting im September 2003 01.10.20 15
TPM – Requirements and opportunities
First, we have to understand how the operator’s job and their system changes
in the culture of TPM!
DS-TC/Klaus Zimmermann, Manager Training und Consulting Europa Manager Meeting im September 2003 01.10.20 16
Requirements and opportunities for Festo – End-user focus
What consequences does the new job have for operators?
DS-TC/Klaus Zimmermann, Manager Training und Consulting Europa Manager Meeting im September 2003 01.10.20 17
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
DS-TC/Klaus Zimmermann, Manager Training und Consulting Europa Manager Meeting im September 2003 01.10.20 18
Example of Visual Management
DS-TC/Klaus Zimmermann, Manager Training und Consulting Europa Manager Meeting im September 2003 01.10.20 19
Example of Visual Management
1 Pressure
0-6 bar
Air supply
Air outlet
MAX
Water
separator MIN Lubricator
2 3
DS-TC/Klaus Zimmermann, Manager Training und Consulting Europa Manager Meeting im September 2003 01.10.20 20
Example of low-cost automation of order picking
DS-TC/Klaus Zimmermann, Manager Training und Consulting Europa Manager Meeting im September 2003 01.10.20 21