TPM and Manufacturing Agility Adrian Pask Vorne Industries

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

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

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”?

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

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)

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?

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?

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

TPM Results From Seiichi Nakajima’s TPM results (1988): Operational rates (speed) improved 17% Breakdowns reduced 98% Value per person increased 140% Maintenance costs reduced 30% Energy consumption reduced 30% Inventory can reduced 50% Leading to improved labor productivity 40-50% Pretty interesting stuff ?!

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.

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

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

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”

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”

Modern TPM – “The Pillar Model” !

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,

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

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.

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

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

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

Want to know more?

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

Want to know more? Visit our website at www.leanproduction.com

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