1. TPM and Manufacturing Agility
Adrian Pask
Vorne Industries

2. My Name is Adrian…. The “Commercial Disclaimer”
We make bolt-on OEE systems
15,000+ installations, over 50 on envelope processes, (several customers in the room?!)
I help people improve productivity using data

3. Thank you for inviting me back
Driving Change with Data
Relationship between Information and Results
Overall Equipment Effectiveness

4. This Morning Agile Manufacturing Total Productive Maintenance (TPM)
“Back to basics” with Seiichi Nakajima
Losing agility in a maze of complexity
What did you think of when you saw TPM?
Did you think of words like “Easy”, “Simple”, “We can do this”……or did you think more “Complicated”, “Big”, and “Difficult”?

5. Our Journey Today Agility as a way of life in Vorne Industries
TPM Origins, Intent, and Results
Losing Simplicity under Complexity
Practical steps you can take to improve manufacturing productivity with TPM

6. Agile Software Development
Vorne: Manufacturer and an embedded software company
From Waterfall to Agile
“Deliver small chunks of business value in short release cycles. For each cycle choose what will deliver the most value, and get it done. Do away with complicated master plans and be evolutionary and adaptive”
(Perfectproduction.com)

7. Agile Software Development
Vision: Ultimate objective for the business
Roadmap: Collection of key deliverables to achieve the objective (nominally 18 months)
Release: The most important stories to deliver next in a meaningful time period (nominally 3 months)
Iteration: A short work cycle in which a meaningful delivery is made (nominally 2 weeks)
Day: What did I complete? What will I complete? What potential impediments do I have?

8. Why Bring Up Agile Planning?
As an Agile business we are:
More responsive
Free to work on what’s important, by letting go of what’s not
Continually improving our processes
It’s the foundation of Vorne’s future, and not just in our engineering department
I’m excited that it’s the theme of this event, how does it work with TPM?

9. What is TPM? Achieving Perfect Production (100% OEE): By: To:
No Breakdowns
No Small Stops or Slow Running
No Defects
By:
Measuring losses
Educating, engaging, and supporting people
With an agile process
To:
Create shared responsibility for machine performance
Save huge amounts of money

10. TPM Results From Seiichi Nakajima’s TPM results (1988):
Operational rates (speed) improved 17%
Breakdowns reduced %
Value per person increased %
Maintenance costs reduced 30%
Energy consumption reduced 30%
Inventory can reduced 50%
Leading to improved labor productivity %
Pretty interesting stuff ?!

11. Where did TPM come from? 1950’s: Preventative Maintenance in the USA
1960’s: Productive Maintenance in the USA
1971: TPM developed by Seiichi Nakajima as a consultant for the Japanese Institute of Plant Maintenance with an accreditation process
1987: Introduced to the USA
1988: First book on TPM was published
Was not developed in or by Toyota, but 60% of the 116 winning plants in the 1980s were Toyota Group companies, or their suppliers.

12. American Productive Maintenance
Seichii: “Total Productive Maintenance is American-style Productive Maintenance, modified and enhanced to fit the Japanese industrial environment”
What he means by this:
American PM was characterized by a pronounced divide between operations and maintenance personnel
The “Total” part of TPM refers to “Total” inclusion.
The goal of TPM is to give operators total ownership of equipment

13. How do you deploy TPM?
Big Enough Reason to Change – why will you “Stick with it”?
Effective Leadership – how will you “Stick with it”

14. Seiichi: How do you deploy TPM?
Maximize Equipment Effectiveness
Establish a maintenance plan for the life span of each machine
Implement across all departments
Involve every employee with training and improvement activities
Develop Productive Maintenance through motivational management “Autonomous Maintenance”

15. Seiichi: TPM Implementation Plan
12 Steps
Steps 1 – 5: Preparation. Education. Creating Teams. Establishing goals. Preparing resources and budgets.
Step 6: Kick Off (by telling your suppliers + clients!)
Step 7: Measure and improve OEE with everyone
Step 8: Develop Autonomous Maintenance with everyone
Step 9: Develop Scheduled Maintenance with everyone
Step 10: Train everyone and update processes
Step 11: Develop Early Equipment Maintenance with everyone
Step 12: Apply for a prize and set new goals !!
“TPM”

16. Modern TPM – “The Pillar Model” !

17. Complexity (from simplicity)
Overall Equipment Effectiveness
Three Big Losses: Availability, Performance, Quality
Seiichi Six Big Losses: Equipment Failure, Setup and Adjustment, Idling and Minor Stops, Reduced Speed, Defects in Process, Reduced Yield
The myth of world class being 85% comes form one of the early books on TPM by Nakajima. He correctly stated that at the tome (pre 1960!) in a machine shop supporting ship building that world class availability should have no more than 10% of time for set up (zero breakdowns) speed losses of no more than 5% (to allow for less than 100% throughput during start up, and 99% right first time quality, This has been misquoted for years, A process plant running at 85% OEE would be a loss making plant,

18. Complexity (from simplicity)
JIPM (the creators of OEE) have 16 Big Losses !!

19. We’ve hidden the essential truth…
…that improvement is about people… ….about people working on the right things, at the right time based on the information you have available.

20. What’s covering the diamond?
In my opinion….
Labour Relationships:
The artificial difference between Leadership, Maintenance, Engineering, and Operations
Culture:
It’s easier to work on machines than to work with people
It takes real investment to educate and train people
Complexity:
The people that deploy TPM “for” you benefit from complexity

21. Where do we start? Awareness
Of the relationships and skills within your team
Of the components in a TPM journey
Of how well you’re running right now (OEE)
Decide
Is this something you want to do?
Commit
Document your Vision and simple Roadmap deliverables (Agile)
Act
Get started by picking a Pilot area

22. Simplified Roadmap (obviously not the only way to implement TPM)
Pick a Pilot Area and set goals
Train and Educate
Restore Equipment to Prime Operating Condition
Implement OEE
Focused Improvement on a Top Loss
Maintenance
Autonomous

23. Want to know more?

24. Want to know more? Available on Amazon about $40 each
Excellent, practical guidance not “theory” based
Strong focus on Leadership and enabling resources

25. Want to know more?
Visit our website at

26. Over ½ this TPM book covers leading and managing TPM projects – including a chapter on making decent feedback presentations