TPM TPM
TPM TPM TPM TPM TPM TPM TPM : (TPM)MP (Synergy) ii
Abstract There are over 60 companies, which have had the experience in TPM implementation, but only 12 companies have got TPM Award until 2000. We may pose this issue, since they have the same TPM system and similar implementing structure/procedure or even the identical consultant, they have obtained total different result, what on earth it is? I attribute this different result to the incitement of teamwork, as well as different management style which may leads to the different achievement of TPM. Herewith, we will review firstly the theoretic character of TPM, and then study the theory of leadership, teamwork and synergy. After that, we will work out the inference of successful mode for the implementation of TPM. According to theoretic inference, a questionnaire was made, which had been listed questions on the basic information of company, the management style of key leader and promoting team of TPM. Above all, TPM performance is also included. This report will review all theoretic inference, and compare to the statistical result of questionnaire, which makes me organize a practical as well as successful mode, i.e. proper leadership and appropriate teamwork leads to high performance of TPM activity. Key Word: Total Productive Management (TPM), MP (Maintenance Prevention) Information, Management Style, Team Work and Synergy. iii
iv TPM)
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WTO Total Productive Management,TPM) TPM TPM MP TPM TPM 1
TPM TPM TPM 2
3
4
TPM) Preventive Maintance) (BM: Breakdown Maintenance) 1954 (G.E.:General Electrics Co.) (Productive Maintenance) (CM:Corrective Maintenance) 1971 (Total Productive Maintenance ) (Total Productivity Management TPM) : TPM) 5
6
Productive Maintenance) 7
8
9
10
11
12
13
2-2 14
2-3 15
No. 1 2 3 1 2 100(%) 3 ( ) 4 ( ) (P) 5 ( ) 6 100(%) ( ) 7 100(%) ( ) 8 100(%) ( ) 9 100(%) ( ) 10 100(%) ( ) 16
(Q) 11 100(%) 1 (%) 100 2 ( ) No. (C) (D) 1 2 ( 1 ) 100(%) 3 ( 1 ) 100(%) 1 100(%) 2 (S) (M) 1 2 1, 000 3 1,000, 000 1 2 3 4 5 6 100(%) 1,000 100 17
18
19
20
21
22
23
24 2-4
25
26
2-5 2-5 27
28
29
2-6 MTBF Mean Time Between Failure; MTTRMean Time To Repair 30
31
32 2-10
33
2-10 34
35 2-8 DR
36
2-9 37
38
39
40
41
2-7-2. 42
43
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45 TPM TPM TPM
46
47
48
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50 Ros Jay(1998) Build a Great TeamP.16~P.34
Jay(1998) 51
52
53
54 Jay(1998) Jay(1998)
Jay(1998) ( ) Spiegel & Torres(1996) 55
Jay(1998) Spiegel & Torres(1996) TPM 1. 2. 3. ( ) 4. 5. 6. 7. 8. 9. 10. Spiegel & Torres(1996) Spiegel & Torres(1996) 56
3-2 57
2-3-2 58
3-1 59
TPM (Synergy)Miller(1992) Miller ( ) : 60
( ) 61
TPM TPM 62
1. TOP TPM TPM 2. TPM 3. TPM TPM 4. TPM 5. TPM OPL 6. TPM 7. TPM Kick-Off 8. TPM TPM 9. TPM 10. TPM 11. MasterPlan 12. 13. 14. Why Why PM MP 15. TPM 16. 17. 18. TPM TopDown 19. PM TPM 63
64 1. 2. 3. 4. 5. 6.
65
( ) 66
(Synergy) 67
TPM AB A B A A1 12 2000 A 21 2000 B 40 60 69
minitab 1. 2. TPM 3. TPM 4. TPM 5. TPM 6. TPM 7. TPM 8. TPM 9. TPM 10. TPM 11. TPM TPM 70
71
1. 1.88:1 TPM 2. 141.94% (1/4) (1/3) 72
5-1: TPM O.E.E % % % % 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1.17 0.84 1.55 1.69 0.92 1.67 0.90 3.35 2.76 18.01 4.74 1.03 1.82 2.32 1.43 2.06 120 131 130 157 120 130 110 99 210 160 210 130 108 112 130 214 122.0 127.5 115.0 162.0 110.0 146.0 105.0 105.0 187.0 150.0 170.0 113.7 104.0 117.5 185.0 133.0 26.5 25.0 28.6 20.0 16.0 20.0 18.0 23.3 50.0 20.0 30.0 25.9 15.0 28.3 33.3 4.0 85.0 33.0 7.4 0.0 50.0 6.0 83.0 43.0 55.0 10.0 20.0 6.3 90.0 5.6 4.5 16.0 2.89 141.94 134.54 23.99 32.18 *1.88 % 2 0 0 1 5 0 1 0 0 1.0 1.5?? 2.0 73
( ) 210+ x x x - - - - 175+ - - x % - x - 140+ - xx x x x - - x x - x x 105+ x - x +--------+--------+--------+--------+-------+- 0 700 1400 2100 2800 3500 5-2 74
1 9 0 1 8 0 % O.E.E 1 7 0 1 6 0 1 5 0 1 4 0 1 3 0 1 2 0 1 1 0 1 0 0 0 1 0 20 5-3 75
190 180 % O.E.E 170 160 150 140 130 120 110 100 1 2 3 4 5 5-4 76
O.E.E. 5-5 O.E.E. 185.25 % 127.75 166.25 124.75 O.E.E % 127.75 185.25 124.75 166.25 77
9 8 7 6 5 4 3 2 1 0 1 2 3 4 78
4 3 2 1 0 1 2 3 4 5 6 7 8 9 1 0 79
O - - E 175+ E % - 140+ - x - x - x - x - x x - x - x - 2 - x x x 105+ 2 x - --+---+-------+-------+-------+-------+------+ 1 2 3 4 5 6 7 8 9 10 12 80
- 180+ - x x - O - - x - x E 150+ x E - x - % - - x 120+ 2 - x x - x 2 - x - +--------+--------+--------+--------+------- 0.0 1 2 3 4 5 / 5-9 81
x 210+ x x - - - - 175+ - - - 140+ - x - 2 x 2 - - 2 % - x x 105+ x - x ------+--------+--------+-------+--------+ 1.0 2.0 3.0 4.0 5.0 x 82
- 180+ - x x - O - - x - x E 150+ x E - x - % - - x 120+ 2 - x x - x 2 - x - +---------+-------+--------+--------+--------- 0.0 1.0 2.0 3.0 4.0 5.0 83
- - x x 180+ - - x O - x E - E 150+ x % - x - - - x 120+ x x - x x - 2 x - x - +---------+---------+--------+-------+------+ 40.0 45.0 50.0 55.0 60.0 84
- - - x - x O 175+ E - x E - x % - - x x 140+ - - x - 2 - x x x 105+ x x x - +---------+--------+-------+-------+-------+ 10.0 15.0 20.0 25.0 30.0 35.0 5-13 TP 85
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1 2 3 4 5 190 180 170 160 150 O.E.E % 140 130 120 110 100 3.0 3.5 4.0 5-14 TPM O.E.E. 87
1 9 0 1 8 0 % O.E.E 1 7 0 1 6 0 1 5 0 1 4 0 1 3 0 1 2 0 1 1 0 1 0 0 3 0 4 0 5 0 5-1 5 O.E.E. % O.E.E 1 9 0 1 8 0 1 7 0 1 6 0 1 5 0 1 4 0 1 3 0 1 2 0 1 1 0 1 0 0 1 0 1 5 2 0 2 5 3 0 3 5 5-1 6 O.E.E. 88
1 90 1 80 % O.E.E 1 70 1 60 1 50 1 40 1 30 1 20 1 10 1 00 1 2 3?? 4 5-1 7 O.E.E. 5-5 89
90 8 7 6 5 4 3 2 1 190 180 170 160 150 140 130 120 110 100 O.E.E % 5-18 O.E.E.
3D(Data,Deviation,Defect) / TPM TPM 91
- - x x 180+ - O.E.E - x - x - 150+ x - x - - x - x 120+ x x - x x - x x x - x - ----+-------+-------+--------+--------+-------+-- 1990.0 1992.0 1994.0 1996.0 1998.0 2000.0 5-19 OEE TPM 92
93 3. 1/3 2/3 4. 2/3 1/3 5. 3 5-6 TPM (%) (%) (%) (%) (%) (%) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 15.0 * 32.5 * 85.0 50.0 85.0 * 39.0 77.0 22.0 17.8 97.0 * 46.0 70.0 53.0% 1/2 20.0 42.0 90.0 38.0 95.0 70.0 85.0 * * 3.0 * 61.3 56.0% 1/2 18 * 92 60 79 * 90 * * 63 * 50 70 65.3% 2/3 17.0 * 6.7 0.0 60.0 * 90.0 * * 25.0 * 12.0 97.0 * 20.0 36.4% 1/3 130 715 428 273 150 300 135 * 700 400 * * 100 200 195 400 317.4% 3 15 5 0 0 0 0 50 0 * 0 * 0 * 0 * 0 5.8% 100%(1996 100% )
1. 10~20% 2. TPM 5%~10% 5-7 (NT$): M: %: 1 2 3 4 5 6 7 8 9 10 11 12 272M 30M 41M 20% 10% 23M 3.8M 1.50% 4.00% 5.12% 5.00% 10.00% 10.00% 10.00% 40.00% 2.70% 94
5-8 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 95
5 9 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 18% 13. 14. 15. 96
97 () ()
98
5-11 1. 2. 3. 4. 5. 6. 7. 8. 9. 99
100
101 TPM
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1. 2. 3. 4. 5. TPM TPM 6. 30 7. TPM 8. ( 89) 103
8. 104
105 3 TPM 10~20% 5%~10%
14. 15. 106
TPM TPM 10~20% 5%~10% 6-1 2-5 5-1,5-6 107
5-1,5-6 108
109
1. TOP TPM TPM 2. TPM 3. TPM 10~20% TPM 5%~10% 4. TPM 5. TPM OPL 6. TPM 7. TPM Kick-Off Kick-Off 8. TPM TPM 9. TPM 10. TPM 11. Master Plan 12. 13. 14. Why Why PM MP 15. TPM 16. 17. 18. TPM TopDown 19. PM TPM 110
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DanzigRobert J.The leader within you: master 9 powers to be the leader you always wanted to be JayRos Build a Great Team 113
Spiegel Jerry & TorresCresencioManager s Official Guide To Team Working 114
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100% 1. P: : 100% % : 100% % : 100% % 2. Q: : 100% % 3. C: : 100% % : 100% % LOSS : 100% % : 100% % : 100% % 4. D: : 100% % 5. M: : 100% % 0PL : 100% % 6. S: : 100% % : : 100% % 120
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