TPM, OEE, Total Productive TPM, OEE, Total Productive TPM, OEE, Total Productive TPM, OEE, Total Productive Maintenance Implementation.Maintenance Implementation.Maintenance Implementation.Maintenance Implementation.

Why Lots of Companies Fail During TPM Execution (36 slides)Why Lots of Companies Fail During TPM Execution (36 slides)Why Lots of Companies Fail During TPM Execution (36 slides)Why Lots of Companies Fail During TPM Execution (36 slides)

Skype contact moses.tan70 Email: mosestc@leancostsolutions.com; mosestc@gmail.comMob +65 93213555 - ZenPower International, Singapore

Professor, University of Glasgow, UK

Companies Fail in TPM Execution Companies Fail in TPM Execution Companies Fail in TPM Execution Companies Fail in TPM Execution When They Not Clear About... When They Not Clear About... When They Not Clear About... When They Not Clear About...

(1) TPM Pillar Details & linkages(1) TPM Pillar Details & linkages(1) TPM Pillar Details & linkages(1) TPM Pillar Details & linkages(2) TPM & the Maintenance Dept. Function(2) TPM & the Maintenance Dept. Function(2) TPM & the Maintenance Dept. Function(2) TPM & the Maintenance Dept. Function

(3) Company Priority / resources (3) Company Priority / resources (3) Company Priority / resources (3) Company Priority / resources

Four Core Pillars

Zero BDsZero Defects

Highest OEE / Lowest Product Cost (Zero-Loss / Ideal Cost)

Companies Fail when They don't Companies Fail when They don't Companies Fail when They don't Companies Fail when They don't . . . . Understand TPM's Understand TPM's Understand TPM's Understand TPM's Three KEY Three KEY Three KEY Three KEY . . . . BeliefsBeliefsBeliefsBeliefs1.1.1.1. Every breakdown and defect is due to a Every breakdown and defect is due to a Every breakdown and defect is due to a Every breakdown and defect is due to a deviationdeviationdeviationdeviation . . . . from the required Basic Machine Conditions from the required Basic Machine Conditions from the required Basic Machine Conditions from the required Basic Machine Conditions –––– . . . . Cleanliness, Lubrication, Proper Bolting, Cleanliness, Lubrication, Proper Bolting, Cleanliness, Lubrication, Proper Bolting, Cleanliness, Lubrication, Proper Bolting, Lifespan Lifespan Lifespan Lifespan . . . . Inspection and Inspection and Inspection and Inspection and Part Part Part Part Precision.Precision.Precision.Precision.

2.2.2.2. EEEEvery very very very deviationdeviationdeviationdeviation is due to a is due to a is due to a is due to a Man-Man-Man-Man-MistakeMistakeMistakeMistake and are and are and are and are .... preventable by preventable by preventable by preventable by Mistake-proofingMistake-proofingMistake-proofingMistake-proofing (Poka-Yoke). (Poka-Yoke). (Poka-Yoke). (Poka-Yoke).

� Manufacturing Excellence is sustained by building a Manufacturing Excellence is sustained by building a Manufacturing Excellence is sustained by building a Manufacturing Excellence is sustained by building a . . . . CI CI CI CI ....Knowledge BankKnowledge BankKnowledge BankKnowledge Bank to to to to revise the PMrevise the PMrevise the PMrevise the PM shut-down Job-shut-down Job-shut-down Job-shut-down Job- . . . . listlistlistlist and and and and shared shared shared shared totototo AM activities AM activities AM activities AM activities.... 3

How TPM Pillars Are Linked

5

Planned Maintenance ( Zero BDs )

Quality Maintenance (Zero Defects )(Poka Yoke)

Autonomous Maintenance Pillar (eyes, ears,hands helping Maint)

Maintenance Knowledge bankMaintenance Knowledge bankMaintenance Knowledge bankMaintenance Knowledge bank

Focused Improvement(100% OEE) (Cost Reduction)

Enhanced PM Joblist for Maintenance Department

6

TPM End-State GoalsTPM End-State GoalsTPM End-State GoalsTPM End-State Goals

BeforeBeforeBeforeBefore: : : :

“X” Shut-Down PM Job-List

After: New After: New After: New After: New

Revised Revised Revised Revised “X” Shut-Down PM Job-list.

Autonomous Maintenance

---- All other Pillars contributions All other Pillars contributions All other Pillars contributions All other Pillars contributions

---- Improved OEE ( BD, DefImproved OEE ( BD, DefImproved OEE ( BD, DefImproved OEE ( BD, Defects.ects.ects.ects.....Jams, Jams, Jams, Jams, Setup, Speed, Startup and Setup, Speed, Startup and Setup, Speed, Startup and Setup, Speed, Startup and ....Blade-Blade-Blade-Blade-change losses) .change losses) .change losses) .change losses) .

From AM3: Initial Maintenance Standards (Knowledge-Bank) From AM3: Initial Maintenance Standards (Knowledge-Bank) From AM3: Initial Maintenance Standards (Knowledge-Bank) From AM3: Initial Maintenance Standards (Knowledge-Bank)

Model Machine

Current PM Job-list Items

Current Items that Need Revision of Stds

New items to be added to PM Job-list

Current PM Job-list items that are OK

NEW PM Job-list items (Total QTY)

AM3 final recommended list

FPP Bagging

36 items 16 44 20 80 items 49 items

NPP Extruder

22 items 4 51 18 73 items 19 items

Enhanced Enhanced Enhanced Enhanced PM Joblist PM Joblist PM Joblist PM Joblist ((((At End of At End of At End of At End of AMAMAMAM Step Step Step Step 3) 3) 3) 3) Real SampleReal SampleReal SampleReal Sample

FM FM FM FM PacPacPacPackkkkGND GND GND GND CutCutCutCut

8

AM Step-by-Step Audit StandardsStep # Step Goal Activity Pass-Standard.Step # Step Goal Activity Pass-Standard.Step # Step Goal Activity Pass-Standard.Step # Step Goal Activity Pass-Standard.

Step 0 Prepare F-Tagging Map Grasp the current Machine F-Map (what/where)Step 0 Prepare F-Tagging Map Grasp the current Machine F-Map (what/where)Step 0 Prepare F-Tagging Map Grasp the current Machine F-Map (what/where)Step 0 Prepare F-Tagging Map Grasp the current Machine F-Map (what/where) Breakdown history Breakdown history Breakdown history Breakdown history

Step-1 Restoration Cleaning & Inspection => 85% repair rateStep-1 Restoration Cleaning & Inspection => 85% repair rateStep-1 Restoration Cleaning & Inspection => 85% repair rateStep-1 Restoration Cleaning & Inspection => 85% repair rate Step-2a Eliminate Sources of KaiStep-2a Eliminate Sources of KaiStep-2a Eliminate Sources of KaiStep-2a Eliminate Sources of Kai’’’’zen improvements =>70% effective effort tozen improvements =>70% effective effort tozen improvements =>70% effective effort tozen improvements =>70% effective effort to Contamination reduce Contamination. Contamination reduce Contamination. Contamination reduce Contamination. Contamination reduce Contamination.

Step-2b Improve Equipment KaiStep-2b Improve Equipment KaiStep-2b Improve Equipment KaiStep-2b Improve Equipment Kai’’’’zen improvements =>70% effective effort tozen improvements =>70% effective effort tozen improvements =>70% effective effort tozen improvements =>70% effective effort to Accessibility improve Accessibility. Accessibility improve Accessibility. Accessibility improve Accessibility. Accessibility improve Accessibility. Step-3 Initial Maintenance Stds. Equipment-knowledgeable =>50% reduced Sudden Step-3 Initial Maintenance Stds. Equipment-knowledgeable =>50% reduced Sudden Step-3 Initial Maintenance Stds. Equipment-knowledgeable =>50% reduced Sudden Step-3 Initial Maintenance Stds. Equipment-knowledgeable =>50% reduced Sudden

operators. operators. operators. operators. breakdowns. breakdowns. breakdowns. breakdowns.

Step-4 General Inspection Skills General check-up of => 90% reduced SuddenStep-4 General Inspection Skills General check-up of => 90% reduced SuddenStep-4 General Inspection Skills General check-up of => 90% reduced SuddenStep-4 General Inspection Skills General check-up of => 90% reduced Sudden Training & Implement equipment by operators. breakdowns. Training & Implement equipment by operators. breakdowns. Training & Implement equipment by operators. breakdowns. Training & Implement equipment by operators. breakdowns.

Step-Step-Step-Step-5/5/5/5/6 Autonomous Inspection AM/Pl Maint. responsibility => 95% reduced Sudden6 Autonomous Inspection AM/Pl Maint. responsibility => 95% reduced Sudden6 Autonomous Inspection AM/Pl Maint. responsibility => 95% reduced Sudden6 Autonomous Inspection AM/Pl Maint. responsibility => 95% reduced Sudden optimized. breakdowns. optimized. breakdowns. optimized. breakdowns. optimized. breakdowns.

Step-7 Organize & manage Self Managing Work TBD.Step-7 Organize & manage Self Managing Work TBD.Step-7 Organize & manage Self Managing Work TBD.Step-7 Organize & manage Self Managing Work TBD. workplace. Teams. workplace. Teams. workplace. Teams. workplace. Teams.

9

Start at Start at Start at Start at AMAMAMAM0 - Baseline Status0 - Baseline Status0 - Baseline Status0 - Baseline Status�Prepared by Maintenance personnel.

� Systematize Defect and Breakdown knowledge in terms of the 5 Basic Machine Conditions (BMCs)

� TPM believes that zero breakdowns and zero defect can be achieved if the BMCs ( free of Contamination, correct lubrication, correct bolting, correct inspection and correct precision of machine functional parts) are strictly controlled.

� Provides a starting baseline from which Step AM1 Activities for Continous Improvement is launched.

AM0 F-Map To Help Find Fuguai PlanPlanPlanPlan forforforfor AM1AM1AM1AM1 CleaningCleaningCleaningCleaning &&&& InvestigationInvestigationInvestigationInvestigation MapMapMapMap (For AM2a,2b - Eliminate Contamination & Improve Accessibil ity)

Team:Team:Team:Team: LegacyLegacyLegacyLegacy TeamTeamTeamTeam

AssemblyAssemblyAssemblyAssembly #1:#1:#1:#1: InputInputInputInput LoaderLoaderLoaderLoader AssemblyAssemblyAssemblyAssembly BMCsBMCsBMCsBMCs extractedextractedextractedextracted fromfromfromfrom RCARCARCARCA BMCBMCBMCBMC GpGpGpGp ListListListList ofofofof FuguaiFuguaiFuguaiFuguai RestorationRestorationRestorationRestoration ofofofof FuguaiFuguaiFuguaiFuguai

CannotCannotCannotCannot loadloadloadload devicedevicedevicedevice intointointointo expansionexpansionexpansionexpansion tracktracktracktrack

BD1 BD1.BD1.BD1.BD1. CannotCannotCannotCannot loadloadloadload devicedevicedevicedevice intointointointo expansionexpansionexpansionexpansion track.track.track.track. 1a1 Loader stop pin damage. 3a FR None None1a2 Worn-out expansion track 3c FR None None1a3 Up/down reflective sensor loose connection. 1 FL None None1a4 Bolts not properly tight that hold up/down reflective sensor. BR None None1a5 Bolts not properly tight that hold flag loader position lock pin. BR None None

1a6 Worn-out loader pivot FR None None 1a7 Bolts not properly tight that hold insert loader pivot. BR None None

1a8 Bolts not properly tight that hold wheel singulator drive. BR None None

FuguaiFuguaiFuguaiFuguai discovereddiscovereddiscovereddiscovered duringduringduringduring FFFF----TaggingTaggingTaggingTagging BMCBMCBMCBMC GpGpGpGp1b11b11b11b1 Bolt 6-32 MissingMissingMissingMissing Completion1b21b21b21b2 Gasket DamageDamageDamageDamage Replaced1b31b31b31b3 Lock washer 6-32 MissingMissingMissingMissing Completion1b41b41b41b4 Insert loader pivot 2b NoneNoneNoneNone None1b51b51b51b5 bolts 6-32 loader pivot insert WrongWrongWrongWrong screwscrewscrewscrew Replaced1b61b61b61b6 Pin loader pivot 2a NoneNoneNoneNone None1b71b71b71b7 Loader base mounting 4b NoneNoneNoneNone None1b81b81b81b8 Loader base 4a NoneNoneNoneNone None1b91b91b91b9 Flag loader stop pin 3b NoneNoneNoneNone None

1b101b101b101b10 Loader pivot spring DamageDamageDamageDamage Replaced1b111b111b111b11 Miniature basic switch DamageDamageDamageDamage terminalterminalterminalterminal supplysupplysupplysupply Replaced1b121b121b121b12 Button loader pivot wornwornwornworn outoutoutout Replaced1b131b131b131b13 Spring clamp magazine wornwornwornworn outoutoutout Replaced

Total:Total:Total:Total: 8888 FuguaisFuguaisFuguaisFuguais

AssemblyAssemblyAssemblyAssembly #### 2222 :::: StorageStorageStorageStorage AssemblyAssemblyAssemblyAssembly BMCsBMCsBMCsBMCs extractedextractedextractedextracted fromfromfromfrom RCARCARCARCA BMCBMCBMCBMC GpGpGpGp ListListListList ofofofof FuguaiFuguaiFuguaiFuguai

3a

3c

2b

3b

4a

4b

2a

1

Left

Right

Right

Left

11

( Step-1 : Restoration & Investigation )( Step-1 : Restoration & Investigation )( Step-1 : Restoration & Investigation )( Step-1 : Restoration & Investigation )( Step-1 : Restoration & Investigation )( Step-1 : Restoration & Investigation )( Step-1 : Restoration & Investigation )( Step-1 : Restoration & Investigation )

OPERATORS

LEADER

MAINT.STAFF

ENGR.STAFF

CONFIRMATION OF PROGRESSDEPT.CHIEF

SUPERVISORSGROUP LEADER

LIST OF EXT/INTABNORMALITIES

MEETING TOPLAN COUNTERMEASURES

COUNTERMEASURES

STEP-1 AUDITMODEL MACHINE

MAINTENANCESTAFF

ENGINEERING STAFF

AUTONOMOUSMAINTENANCEGROUP

FOLLOW UP ON AUDITFEEDBACK

COUNTERMEASURESEXTENDED TO ALL

EQUIPMENTAUDIT

DEPT.CHIEF

LEADER

SUPERVISORS

TO NEXT STEP

Find Contam & Access SamplePlanPlanPlanPlan forforforfor AM1AM1AM1AM1 CleaningCleaningCleaningCleaning &&&& InvestigationInvestigationInvestigationInvestigation MapMapMapMap (For AM2a,2b - Eliminate Contamination & Improve Accessibility)

Team:Team:Team:Team: BaggingBaggingBaggingBagging Team.Team.Team.Team. Equipment:Equipment:Equipment:Equipment: BaggingBaggingBaggingBagging MCMCMCMC

AssemblyAssemblyAssemblyAssembly #1:#1:#1:#1: BagBagBagBag PickingPickingPickingPicking AssyAssyAssyAssy BMCsBMCsBMCsBMCs extractedextractedextractedextracted fromfromfromfrom RCARCARCARCA DescribeDescribeDescribeDescribe ContaminationContaminationContaminationContamination AccessibilityAccessibilityAccessibilityAccessibility problemsproblemsproblemsproblemsBD1.Bag Picking Assy cannot pick bag Contamination

to the roller printer. 1a3) Cleaning the air f ilter. BD#1a - Vac Cup Suction Low * No standing space to remove and

1a1) Suction cup w orn/harden replace f ilter.1a2) Suction tubes loose/broke1a3) Air f ilter clogged 1a3) Air f ilter clogged Other BMC Groups1a4) Pump impeller broke * Water f rom air suppy IA. 1a4) Pump impeller 1a5) Pump motor burned * Collected on f ilter elements * Inside assembly cannot see.

1a6) Pump bearing w orn * From Air Compressor. 1a5) Pump motor burned BD#1b - Vac Cup cannot reach Bags. * Affects a new f ilter performance * Inside assembly cannot see.

1b1) Cylinder leakage w ithin 2 w eeks. 1a6) Pump bearing w orn1b2) Solenoid valve jammed * Inside assembly cannot see.1b3) Air f ilter clogged 1b4) No w ater trap

HistoricalHistoricalHistoricalHistorical BMCsBMCsBMCsBMCs (not(not(not(not above)above)above)above)BoltsBoltsBoltsBolts (fuguai/contam/Access)(fuguai/contam/Access)(fuguai/contam/Access)(fuguai/contam/Access)LubrLubrLubrLubr (fuguai/contam/Access)(fuguai/contam/Access)(fuguai/contam/Access)(fuguai/contam/Access)

Future BD Areas to be investigated: BMCsBMCsBMCsBMCs fromfromfromfrom FuguaiFuguaiFuguaiFuguai FoundFoundFoundFound DescribeDescribeDescribeDescribe ContaminationContaminationContaminationContamination AccessibilityAccessibilityAccessibilityAccessibility problemsproblemsproblemsproblemsContamination

1) Remove covers of gear assembly Tag 1-FR : Belts w ere w orn and Tag 3-Contam: Dust over elect Tag 3-Contam: Dust over electhousing and do a clean/tag of the belts, have play. w ires and joints. w ires and joints.gears and electrical contacts. Tag 2-FR/Lubr : Gear Assy * dust f rom environment enter * Need to remove 8 screw s

movements noisy through vent gaps over time. to take out covers. rustand no lubricant.

Tag 3-Contam: Dust over electw ires and joints.

More Before & After Pictures

13

(Note: Need To Raise Maintenance Work Order For F-Tag Repairs)

AM1AM1AM1AM1 ProvisionalProvisionalProvisionalProvisional CleaningCleaningCleaningCleaning MonthlyMonthlyMonthlyMonthly CalendarCalendarCalendarCalendar

Machine name: REACTOR POL MP2 No of machine: 3 Month:

No. ID Code Assembly Cleaning Item Criteria Method Tool Date

Cleaning area ( Diagram)OneOneOneOne PerPerPerPer WeekWeekWeekWeek 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

1 1111 Floor Reactor Floor No chemical

spillage at floor Clean Mop OOOO OOOO OOOO OOOO OOOO

2 2222 Reactor Reactor Grease chute container

Grease level half of conainer level

Clean Scope OOOO OOOO OOOO OOOO OOOO

3 13131313 Floor Reactor Floor No waste material

at floor Clean Broom OOOO OOOO OOOO OOOO OOOO

4 14141414 Raw Material Feed Line IO-PT Line Bracket No loosen bracket Wiping Cutton rag OOOO OOOO OOOO OOOO OOOO

OneOneOneOne PerPerPerPer MonthMonthMonthMonth 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

5 3333 Hot Water Line hot water flexible hose No spash grease Clean Cutton rag OOOO

6 4444 N2 Line N2 Line to Reactor No rusy Wiping Cutton rag OOOO

7 5555 CHW LineCHW Line to Reactor

Jacket No rusty Wiping Cutton rag OOOO

8 6666 Raw Material Feed DO LineNo rusty and No

leaking Wiping Cutton rag OOOO

9 7777 Reactor Reactor gear housing No contamination stick at housing

Clean Brush and cutton rag OOOO

10 8888 ReactorReactor Vent Line

InsulationProper Heat

Insulation Clean Brush and cutton rag OOOO

11 9999 Reactor CW Line to Reactor No corrosive and

rusty Clean Brush and cutton rag OOOO

12 10101010 ReactorReactor Main Motor

Cooling Fan No hard scale Clean Brush , cotton rag OOOO

13 11111111 ReactorReactor Main Motor

Stand / Stack No rusty Clean Brush and paint OOOO

14 12121212 OthersMain Motor Belt Safety

Cover No rusty Clean Brush and paint OOOO

15 15151515 DO Rounding LineDO / CHW Line

Insulation Proper Installation Wiping Cutton rag OOOO

Before After Before After

15

( Step-2a : Eliminate Sources Of Contamination ) ( Step-2a : Eliminate Sources Of Contamination ) ( Step-2a : Eliminate Sources Of Contamination ) ( Step-2a : Eliminate Sources Of Contamination ) ( Step-2a : Eliminate Sources Of Contamination ) ( Step-2a : Eliminate Sources Of Contamination ) ( Step-2a : Eliminate Sources Of Contamination ) ( Step-2a : Eliminate Sources Of Contamination )

Complete Step-1Complete Step-1Complete Step-1Complete Step-1

Step-1 Summary results & findings

What ?What ?What ?What ?

Where ?Where ?Where ?Where ?

How How How How muchmuchmuchmuch

Why ?Why ?Why ?Why ?

AM Team=> 70%

Countermeasures

1st 1st 1st 1st Pre-Auditby TPM Dept.

Present Countermeasuresto TPM WC andimplementation

GM/Sponsors

Audit

Step-3Step-3Step-3Step-3

Own areaBuy - Off

5. AM2a Contamination Analysis Worksheet (3/5) 5. AM2a Contamination Analysis Worksheet (3/5) 5. AM2a Contamination Analysis Worksheet (3/5) 5. AM2a Contamination Analysis Worksheet (3/5) AM-2A CONTAMINATION ANALYSIS AM-2A CONTAMINATION ANALYSIS AM-2A CONTAMINATION ANALYSIS AM-2A CONTAMINATION ANALYSIS

MACHINE:MACHINE:MACHINE:MACHINE: ASM5500QUESTIONS ABOUT CONTAMINATION SOURCE QUESTIONS ABOUT CONTAMINATION SOURCE QUESTIONS ABOUT CONTAMINATION SOURCE QUESTIONS ABOUT CONTAMINATION SOURCE DURING INVESTIGATIONSDURING INVESTIGATIONSDURING INVESTIGATIONSDURING INVESTIGATIONS

ACTUAL FACTS COLLECTED ACTUAL FACTS COLLECTED ACTUAL FACTS COLLECTED ACTUAL FACTS COLLECTED SKETCH THE CONTAMINATION FALL-PATHSKETCH THE CONTAMINATION FALL-PATHSKETCH THE CONTAMINATION FALL-PATHSKETCH THE CONTAMINATION FALL-PATH

MACHINE SECTION:MACHINE SECTION:MACHINE SECTION:MACHINE SECTION: Waferhandler - Port1 1111 What is it?What is it?What is it?What is it? Broken silicon piecesBroken silicon piecesBroken silicon piecesBroken silicon pieces2222 Where is the source? Where is the source? Where is the source? Where is the source? Wafer protruding from Port1 Elevator cassette3333 How the contamination got there? (The Fall-Path)How the contamination got there? (The Fall-Path)How the contamination got there? (The Fall-Path)How the contamination got there? (The Fall-Path) Not fully inserted because cassette was not seated

properly then smashed against lid housing upon port initialise

CONTAMINATION TYPE:CONTAMINATION TYPE:CONTAMINATION TYPE:CONTAMINATION TYPE: Broken wafer 4444 Why is the contamination there?Why is the contamination there?Why is the contamination there?Why is the contamination there? Wafer not fully inserted5555 When it get there?When it get there?When it get there?When it get there? Upon impact with underside of lid housing

REFERENCE # :REFERENCE # :REFERENCE # :REFERENCE # : CONTAMINATION BASELINECONTAMINATION BASELINECONTAMINATION BASELINECONTAMINATION BASELINE BASELINE MEASUREMENTBASELINE MEASUREMENTBASELINE MEASUREMENTBASELINE MEASUREMENTa)a)a)a) HOW MUCH? ( volume, weight, count or an actual HOW MUCH? ( volume, weight, count or an actual HOW MUCH? ( volume, weight, count or an actual HOW MUCH? ( volume, weight, count or an actual

sample)sample)sample)sample)1 broken wafer on 5 areas indicated

CONTAMINATION EFFECT :CONTAMINATION EFFECT :CONTAMINATION EFFECT :CONTAMINATION EFFECT :b)b)b)b) HOW LONG? - (Record the time for the Qty of HOW LONG? - (Record the time for the Qty of HOW LONG? - (Record the time for the Qty of HOW LONG? - (Record the time for the Qty of

contamination to accumulate) contamination to accumulate) contamination to accumulate) contamination to accumulate) 6 Months

BreakdownBreakdownBreakdownBreakdownDefectDefectDefectDefectContaminate LubricationContaminate LubricationContaminate LubricationContaminate Lubrication

xxxx General Area contaminationGeneral Area contaminationGeneral Area contaminationGeneral Area contamination

7. JH AM2a Audit Standards & Results.7. JH AM2a Audit Standards & Results.7. JH AM2a Audit Standards & Results.7. JH AM2a Audit Standards & Results.AREAAREAAREAAREA ELEMENTSELEMENTSELEMENTSELEMENTS MAXMAXMAXMAX POORPOORPOORPOOR GOODGOODGOODGOOD EXCELLENTEXCELLENTEXCELLENTEXCELLENT PTSPTSPTSPTS COMMENTS FOR SCORE COMMENTS FOR SCORE COMMENTS FOR SCORE COMMENTS FOR SCORE

BELOW MAXIMUMBELOW MAXIMUMBELOW MAXIMUMBELOW MAXIMUM 1. Is the level of cleaning

inspection started in Step 1 maintained as a regular part of the activities?

10101010

Evidence of ineffective cleaning & inspection

0000----3333

Reasonable implementation but can do better

4444----7777

Excellent adherence and embedded as part of process

8888----10101010

10

2. Is there evidence of training and development of members (visual controls, equipment functions, and tools)?

15151515

Little evidence of skill enhancement

0000----5555

Majority are demonstrating significant skills

6666----10101010

High levels of skill evident in the nos. of OPL’s and training

11111111----15151515

15

SK

ILL

UP

GR

AD

ING

SK

ILL

UP

GR

AD

ING

SK

ILL

UP

GR

AD

ING

SK

ILL

UP

GR

AD

ING

3. Are all participating in activities (attendance list)? Is MA able to explain activities & m/c functions? Is Team Leader coordinating activities?

10101010

Low attendance (<80%) and skill development or coordination

0000----3333

Some activity but inadequate development and attendance at <80%

4444----7777

High levels of participation (>80%) and MA are able to explain

8888----10101010

10

4. Are sources of contamination summarized into a list, thoroughly analyzed and effective countermeasures implemented?

15151515

Some information but disorganized

0000----5555

Some activity but generally inadequate

6666----10101010

High levels of activity and progress

11111111----15151515

13

Need to add latest Breakdowns and chronic defects in the Gap Analysis to find more sources of Contamination.

EQ

UIP

ME

NT

STA

EQ

UIP

ME

NT

STA

EQ

UIP

ME

NT

STA

EQ

UIP

ME

NT

STAT

US

TUS

TUS

TUS

5. Are the losses caused by contamination quantified and counter-measures to reduce contamination by >70% effective?

15151515

A vague idea of losses, and not quantified

0000----5555

Some activity in place but improvement to reduce contamination is < 70%

6666----10101010

Very progressive, with clear goals and results are >70% reduction of contamination.

11111111----15151515

15

6. Have maintenance tasks been identified for transfer to operators? Is there a plan to upgrade skills?

5555

Few if any

0000----2222

Some activities are in place but no plans

3333----4444

Skill levels are clear and transfer plans in place

5555

5

IMP

RO

VE

ME

NT

IMP

RO

VE

ME

NT

IMP

RO

VE

ME

NT

IMP

RO

VE

ME

NT

SS S S 7. Are the majority of “efu” closed or planned for closure?

5555

Most “efu” are still pending

0000----2222

Clear progress made on “efu” elimination

3333----4444

Most “efu” are closed or with action plan

5555

5

POTENTIAL SCORE POTENTIAL SCORE POTENTIAL SCORE POTENTIAL SCORE 75757575 ACTUAL SCORE ACTUAL SCORE ACTUAL SCORE ACTUAL SCORE 73737373 Overall = Overall = Overall = Overall = 96.5%96.5%96.5%96.5%

AM2a Audit Standards (JIPM-Compliant) AM2a Audit Standards (JIPM-Compliant) AM2a Audit Standards (JIPM-Compliant) AM2a Audit Standards (JIPM-Compliant)

18

AMAMAMAM2a2a2a2a Benefit: Benefit: Benefit: Benefit:

� AM2a focus against the sources of contamination and achieves => 70% reduction of the contamination baseline.

� By reducing Contamination we reduce machine breakdowns and product defects and makes the machine and workplace cleaner.

19

( Step 2b : Improve Equip Accessibility To Maintain ).( Step 2b : Improve Equip Accessibility To Maintain ).( Step 2b : Improve Equip Accessibility To Maintain ).( Step 2b : Improve Equip Accessibility To Maintain ).

AM LeaderAM LeaderAM LeaderAM Leader Model m/c Model m/c Model m/c Model m/c

Passed Passed Passed Passed Step 2 Step 2 Step 2 Step 2

Areas difficult orAreas difficult orAreas difficult orAreas difficult orinaccessible for cleaninginaccessible for cleaninginaccessible for cleaninginaccessible for cleaningchecking & lubricatingchecking & lubricatingchecking & lubricatingchecking & lubricating

Inaccessible Inaccessible Inaccessible Inaccessible

No Place To No Place To No Place To No Place To Stand Stand Stand Stand

Wiring or piping Wiring or piping Wiring or piping Wiring or pipingobstructobstructobstructobstruct

Cannot see Cannot see Cannot see Cannot see easilyeasilyeasilyeasily

Time ConsumingTime ConsumingTime ConsumingTime Consumingto cleanto cleanto cleanto clean

Time ConsumingTime ConsumingTime ConsumingTime Consumingto cleanto cleanto cleanto clean

Product ManagerProduct ManagerProduct ManagerProduct Manager

Operator Leader/ OperatorsOperator Leader/ OperatorsOperator Leader/ OperatorsOperator Leader/ Operators

SupervisorSupervisorSupervisorSupervisor

Model MachineModel MachineModel MachineModel MachineGoes To Goes To Goes To Goes To

Step 4Step 4Step 4Step 4

Pre-AuditPre-AuditPre-AuditPre-Auditby TPM Deptby TPM Deptby TPM Deptby TPM Dept....

W/C W/C W/C W/CBuy OffBuy OffBuy OffBuy Off

GMGMGMGMAuditAuditAuditAudit

OwnOwnOwnOwnAreaAreaAreaArea

Buy OffBuy OffBuy OffBuy Off

20

AMAMAMAM2b2b2b2b Benefit: Benefit: Benefit: Benefit:� Many maintenance items are Time-consuming and/or Hard-to-Access for Cleaning, Lubrication, Bolting, Inspection and Precision Checks.

� AM2b reduces accessibility time by => 70% of the baseline time.

21

AM3 Benefit:AM3 Benefit:AM3 Benefit:AM3 Benefit:�Based on "total fuguai" data, revise & Improve and expand the PM Job-list

�Operators become all-present Eyes, Ears, Hands For the accessible Sub-set of updated PM Job-list for Cleaning, inspection & precision checks.

Model Machine

Current PM Job-list Items

Current Items that Need Revision of Stds

New items to be added to PM Job-list

Current PM Job-list items that are OK

NEW PM Job-list items (Total QTY)

AM3 final recommended list

FPP Bagging

36 items 16 44 20 80 items 49 items

NPP Extruder

22 items 4 51 18 73 items 19 items

PM Joblist PM Joblist PM Joblist PM Joblist (AM3 Status) Sample Only(AM3 Status) Sample Only(AM3 Status) Sample Only(AM3 Status) Sample Only

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Continuous Im provem ent W orksheet For Updating PM Standards Job-list Item sContinuous Im provem ent W orksheet For Updating PM Standards Job-list Item sContinuous Im provem ent W orksheet For Updating PM Standards Job-list Item sContinuous Im provem ent W orksheet For Updating PM Standards Job-list Item sToolset N ame: Toolset N ame: Toolset N ame: Toolset N ame:

B D #1 Tubes jamB D #1 Tubes jamB D #1 Tubes jamB D #1 Tubes jam M 70SW 11 u/s v Addblocked drive v v ReviseDegraded proxim ity switch v Add

battery valve u/s v Addrot.drive jam , v NCAM 2 C-measures access panel Add

W orn earth wire v AddBD #2 Tubes cant BD #2 Tubes cant BD #2 Tubes cant BD #2 Tubes cant shiftshiftshiftshift

rot.drive jam , v Addproxim ity switch worn v Addtube tower dirty v v Revisecylinder leak v Addsingulator fingers loose v Addtube stack height loosen v Add

Tubes are not moving one by one smoothly and some jammin g are occuring.

Tubes are not able to be shifted one by one smoothly to the Loader Gripper.

New Fuguai Observed during Tagging…New Fuguai Observed during Tagging…New Fuguai Observed during Tagging…New Fuguai Observed during Tagging… . . . .

1. Base Unit 1. Base Unit 1. Base Unit 1. Base Unit Loader. Loader. Loader. Loader. Assy 1-1) Loader Input stack

To hold the tubes of devices while waiting to be loaded into the machine

Assy 1-2 Loader Tube shifter

PM items PM items PM items PM items D ecision D ecision D ecision D ecision a) no change b) revise stds c) add to PM list

Information source Information source Information source Information source (BD/Def/Fuguai/) (BD/Def/Fuguai/) (BD/Def/Fuguai/) (BD/Def/Fuguai/)

2) PM 2) PM 2) PM 2) PM Job-listJob-listJob-listJob-list

System ID - System ID - System ID - System ID - Drive/Elect/Pnue/Hd

y/W ater………… ........

Assy Assy Assy Assy overall overall overall overall function function function function

Early W arning Signs Early W arning Signs Early W arning Signs Early W arning Signs (M C or Product)(M C or Product)(M C or Product)(M C or Product)

M aint Parts M aint Parts M aint Parts M aint Parts Repaired/ ReplacedRepaired/ ReplacedRepaired/ ReplacedRepaired/ Replaced

AM Operators becomes Maintenance DeptAM Operators becomes Maintenance DeptAM Operators becomes Maintenance DeptAM Operators becomes Maintenance Dept’’’’s extra s extra s extra s extra ““““ears, ears, ears, ears, eyes, hands, noseeyes, hands, noseeyes, hands, noseeyes, hands, nose”””” to detect early signs of MC trouble and to detect early signs of MC trouble and to detect early signs of MC trouble and to detect early signs of MC trouble and

thus helped to change Un-Planned Events into Planned thus helped to change Un-Planned Events into Planned thus helped to change Un-Planned Events into Planned thus helped to change Un-Planned Events into Planned Events (Planned Maintenance)Events (Planned Maintenance)Events (Planned Maintenance)Events (Planned Maintenance)

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AM4 Benefit:AM4 Benefit:AM4 Benefit:AM4 Benefit:� Further improve/expand the PM Joblist from successful OEE big losses projects.

� Operators' scope increased, some experienced operators can do line maintenance.

M-Q (Machine-Quality) Summary after solving "Thickness Fails" chronic defect.

Copper Brush, Flipper Spring and Brass Bar.

Plating Chemical

Dryer Heater Corner Spray and Rinsing Water

Dryer Blower

Part of MachinePart of MachinePart of MachinePart of Machine Plating ChemicalPlating ChemicalPlating ChemicalPlating Chemical FlipperFlipperFlipperFlipper B. Bar / C. BrushB. Bar / C. BrushB. Bar / C. BrushB. Bar / C. Brush Dryer HeaterDryer HeaterDryer HeaterDryer Heater

Measurement Chemical Content Tension Contact Pressure Hot Air Temperature

Std. Value MSA: 37.5% +/- 5% Upper <= 250 g Upper = 6 kg/cm Upper = 130 deg. CTIN: 37.5 g/l +/- 5 g/l Nominal = 120g Nominal = 5.5 kg/cm Nominal = 125 deg CAdditive: 2 g/l +/- 0.5 g/l Lower => 60g Lower = 5 kg/cm Lower => 120 deg C

Interval Daily Weekly Forthnightly Daily

Quality Defect Quality Defect Quality Defect Quality DefectThickness FailThickness FailThickness FailThickness Fail Thickness FailThickness FailThickness FailThickness Fail Thickness FailThickness FailThickness FailThickness Fail Thickness FailThickness FailThickness FailThickness Fail

Quality of M/c PartQuality of M/c PartQuality of M/c PartQuality of M/c Part

Circularity

Content ���� O O O

Deterioration

Smoothness

9999 10101010 11111111 12121212 13131313

11112222333344445555

66667777

8888 14141414

Checked by Prepared by Phenomenon Physical view (Logical reasoning)

PM Analysis Chart No 3/5 Illegible or partial marking occurs during the marking process at TM06.

The rubber pad does not transfer a ll the full characters from the stamp plate to the package surface resulting in Illegible Marking

Contributing Condition Investigation Result 4 M Correlation, First Item

Investigation Result4M Correlation,

Second Item Investigation/ Investigation Result If NG, Countermeasure Result

Investigation M easuring Method

Temporary Decision Criterion

Measure - ment Value

DecisionInvestigation/ Measuring

MethodTemporary

Decision CriterionMeasure -

ment ValueDecision

(3rd, 4th, 5th and 6th Items

Measuring Method

Temporary Decision Criterion

Measure - ment Value

Decision why NG?Restoration, Replace - ment, Improvement,

Remodeling

Measurement Value

Decision

3. INCOMPLETEOR INSUFFICIENTDEPTH OF 9 - 11 mils 7 mils NG 3.1 Deterioration 0.49 W - 0.46 W NG 0.50 W OKCHARACTERS of laser Engraver 0.52WON STAMP PLATES. beam power

SIDESIDESIDESIDE VIEWVIEWVIEWVIEW OFOFOFOF PLATEPLATEPLATEPLATE

SIDESIDESIDESIDE VIEWVIEWVIEWVIEW OFOFOFOF PLATEPLATEPLATEPLATE Laser after powerdeterioration

Actual Laser

Characters not beenengraved deeply caused illegible marking. Characters not been

engraved deeply caused illegible marking.

2. Uneven stamp Even layer No method NGplate layer. to measure

3. Residue ink on No ink residue Have ink NG 1. Not fully 1. To immerge 60 to 65 mm OKused plate. in characters residue immerged in Stamp Plate into 75 mm

or stamp plate acetone after use. acetone properly.2. Delayed to 2. Immediately maximum 15 min OKimmerge stamp immerge the plate 30 minin acetone. after use. after 3. Stamp plate usednot cleanedproperly.4. Acetone 4. To change the No No OKcontainer dirty. acetone 2x per week Illegible Illegible

marking. marking.

Design of Experiments During P-M Analysis For Design of Experiments During P-M Analysis For Design of Experiments During P-M Analysis For Design of Experiments During P-M Analysis For Chronic DefectsChronic DefectsChronic DefectsChronic Defects

OEE = Availability x Performance Rate x Quality Rate

OEE Waterfall Chart Single-Dimensional chart (Less Useful)

1. Speed Loss2. MTBA & Idling

OEE Loss Analysis ChartQuantity Vs Time 2-D Chart (More Useful)

Speed Loss(Company gap)

MTBA & Idling

Quality Loss

Speed Loss (World class gap)

Availability Loss

Source: JIPM 2014 Criteria.

frequently Process Improvements takes several months during which unpredictable changes

in energy, materials, overhead costs, new process problems. etc offset or hide the real cost reductions achieve by them causing possible loss of motivationVisit www.leantargetcosting for a software solution.

Using Costs To Drive C.I. Activities Software uses Toyota Principles, TPM OEE, Lean 6S.

Watch on Youtube, Youku, Vimeohttps://www.youtube.com/watch?v=A-YG7K-E-d0

Watch on Youtube, Youku , Vimeo https://www.youtube.com/watch?v=c-sqDNGmSGk&t=10s

Principles of measuring ROI of Lean 6S and TPM OEE Projects - 1min 45s

How to plan X% Product Cost Reduction & link to CI, TPM, Lean 6S - 2min 46s

Notes:1. The Process Yield Project can reduce the Process Cost by 9.21% (Rank 1 ticked)

Note: Red numbers are Cost-Reductions adjusted to Baseline conditions to eliminate noise.

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