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ELIMINATE
&
PREVENT MUDA
federal Tvet agency and EKI 2
Contents
1)The concept of MUDA/Waste
2)Methods for categorizing types of Muda
3)MUDA identification
4)Elimination of Muda
5)Methods for Muda prevention
6)TPM concepts and its pillars
3
1) The concept of Muda
What is Value?
Value is defined by your customer.
There are two types of Customers:-
-Internal customer
-External customer
Then Value is the activity/effect
what the customer exactly is
going to pay for/needs.
federal TVET agency and EKI
federal Tvet agency and EKI 4
What is Waste/MUDA?
• Waste/MUDA is any activity of
workers/machines which consumes resources
such as money, time, energy, materials, etc
without adding value.
federal Tvet agency and EKI 5
The main elements of KAIZEN
management
• Quality (Customer)
• Cost (Company)
• Delivery(Customer)
• QCD is the source of
productivity improvement
federal Tvet agency and EKI 6
C O S T
M
I
N
I
M
I
Z
E
Better Quality
On time
Delivery
Higher
Profit
Profit=Price-Cost
ምን ይሻላል???
CUSTOMER
የትም ፍጭው
ዱቄቱን
አምጭው
Reasonable
Price
MANUFACTURER
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The concept of cost
Cost minimization
• Determination of the sales price of the product
Sales price=(manufacturing)cost + profit
• Manufacturing cost=(material + labor +
facility + utility + others)cost
federal Tvet agency and EKI
PRICE=COST + PROFIT
PROFIT= PRICE - COST
Company sets price(Demand>Supply)
Market sets price (Demand≤Supply)
Traditional Thinking
Kaizen Thinking
8
federal Tvet agency and EKI 9
The three categories of Operations
• Value Adding/Net Operation
• Non Value Adding Operation
• Muda/Waste
federal Tvet agency and EKI 10
The three categories of Operations
(1) Net Operation
• Part of the operation that adds value
to make parts and products
Examples, Milling, Turning, Grinding,
Assembling and Welding
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The three categories of Operations
(2) Non-Value adding Operations
• Operation that adds no value but
cannot be avoided
Example Setting up, Inspecting,
Picking up parts, Removing drill chips
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The three categories of Operations(Cntd)
(3) “Muda”
• Muda is a Japanese word meaning Wasteful
Activity
• Is anything unnecessary in operation.
• Can be eliminated immediately
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The three categories of Operations(Cntd)
(3) “Muda”
• It increases Production cost
• Muda affects the quality of the product
and also delivery time
federal Tvet agency and EKI 14
Non-value adding and
wastes
• movements
• searching for tools
• transporting
materials
• over production
• waiting /idle time
• making defects etc
Value adding
• assembling
• molding
• spinning
• mixing
• building
• milling etc
“Muda” are activities which use resources,
time or cost without adding value.
federal Tvet agency and EKI
Value Chain Consume
rs
Supplier
s
Reduce Lead Time
Non Value Added & Waste activities
15
16
Product Lead-Time
federal Tvet agency and EKI
Raw
Materials
Finished
Goods
Value Added
Time
Non- Value
Added Time
TIME
federal Tvet agency and EKI 17
Very Simple Drill
• Operation to staple two papers using a
stapler when work place is disorganized
• Materials and tools
–Two pieces of paper
–Stapler
–Staples
federal Tvet agency and EKI 18
Very Simple Drill
Result in a disorganized environment
N0. Activities Time Type of
Operation
Measure How
1 Searching for
Stapler
35 Sec Muda Eliminate 5S(Set-in-order)
2 Searching for
Staples
30 Sec Muda Eliminate 5S(Set-in order)
3 Putting the Staples
into the stapler
8 Sec Non-Value
adding
Minimize Load staples
ahead
4 Putting the two
papers
together
3 Sec Non-Value
adding - -
5 Staple the papers 2 sec Net Operation
(Value Adding) - -
federal Tvet agency and EKI 19
Lessons from the drill
• Total time of operation=78 Sec
Net Operation(Value adding)=2 Sec(2.6%)
Non-Value adding operation=11 Sec(14.1%)
Muda(Unnecessary operation)=65Sec(83.3%)
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MUDA = Anything Unnecessary
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2)Methods For Categorizing Types of Muda/Wastes
Classification of waste
A number of methods for classification of waste have
emerged. Here are some of them:-
The 3MU’s
5M+Q+S
The flow of goods
The Seven deadly wastes
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Muda
Muri
Mura
1) The 3MU’s
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MUDA-Capacity exceeds load.
MURA (imbalance or variation) =
capacity sometimes exceeds the load and
the load sometimes exceeds capacity.
MURI(Physical or mental overburden)-
Load exceeds capacity .
Productivity improvement does not
mean hard work.
The Three MU’s
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The Three M’s
Muda
• Production factors that increase
cost, in other words, all
unnecessary things
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The Three M’s (Cntd)
Muri
• Mental and physical overburden on
operators, and overburden on
production machinery
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Muri
We should not force hard work on
Employees in the name of
productivity improvement
Value added work
Working density =
Actual work
The Three M’s (Cntd)
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Muri : overburden
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የስራ ጫና Muri
federal Tvet agency and EKI 30
የስራ ጫና
Muri
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The Three M’s
Mura
• Variation in work distribution,
production capacity of machinery, and
material specifications
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IN OUT
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Relationship between the 3 M’s
• Usually Mura creates Muri which in turn
lead to generation of Muda
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Relationship between the 3 M’s
• Therefore, mura creates muri that
undercuts previous efforts to
eliminate muda.
• Eliminating mura is fundamental to
the complete elimination of muri and
muda
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2) 5M+Q+S
• Is another way of thinking in the areas where
waste may occurs 5M(man, material,machine,
method and management), plus Quality and
Safety.
federal Tvet agency and EKI 37
Contd…
Material
Waste of:- Parts, Bolts, Welds, Functions, Storage & Handling.
Man/Workers
Waste of:- Walking, Waiting, Searching, Unnecessary movements
Management
Waste of:- Materials, Meetings, Management control,
Communications, Vouchers
Machine
Waste of:- Large machines, General purpose machines,
Conveyors, Machines with wasteful movements, Breakdowns,
Machine handling
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Contd….
Method
Waste of:- Large lot production, Inventory,
Conveyance, Retention, Non standardization,
Picking up setting down work pieces.
federal Tvet agency and EKI 39
Contd…
Quality
Waste in:- Making defective goods, Fixing
defects, errors, Inspection, Quality control.
Safety
Waste of:- Disaster prevention methods, Fixing
defects.
federal Tvet agency and EKI 40
3)The Seven deadly wastes
1) “Muda” of Overproduction
2) “Muda” of Inventory
3) “Muda” of Waiting
4) “Muda” in Transporting
5) “Muda” of Defect-making
6) “Muda” of Motion
7) “Muda” in Processing
Cost Reduction by Elimination of
muda
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7 Categories
of Waste
Defect Making
Transportation
Over Produced
Motion
Inventory
Over Processed
Waiting
federal Tvet agency and EKI
1)“Muda” of Overproduction
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To produce things more than necessary in
terms of type, time, and volume. It is called
“the worst kind of Muda” since it hides all the
other wastes.
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1)“Muda” of Overproduction
[Cause]
Excessive work
force and
facilities
Big and fast
production
machine
Lack of customer
focus
[Effect ]
Increase in inventory
Outbreak of defects
Deterioration of turn-
over ratio of funds
Advanced preparation
of materials and parts
Consumes resources
Needless wear on
machines
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2) “Muda” of Inventory
The situation where items such as raw
materials, parts, and finished goods are
stagnant or which are not having value added
to them. Some are located in the warehouses,
and others are in-process inventory.
federal Tvet agency and EKI 45
2) “Muda” of Inventory
[Cause]
 Weak consciousness for
inventory
Bottle-neck processing
stage
 Advanced Production
 Approximate production
 Unreliable suppliers
[Effect ]
 Waste of space
 Needs for inspection,
and transportation
 Expansion of working
fund
 Shelf life may expire
 It ties up cash
 Makes FIFO inventory
management more
difficult
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Examples of Inventory Wastes
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3) “Muda” of Waiting
This includes all kinds of waste of time such as
workers or parts waiting: -for an upstream
process to deliver,
-for a machine to finish processing,
-for incoming parts or materials,
-for process that has a long wait time
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3) “Muda” of Waiting
[Cause]
 Bottle-neck
processing stage
 Bad facility layout
 Capacity imbalance
 Shortages &
unreliable supply
chain
 Lack of multi-skilling
 Poor maintenance.
[Effect ]
Waste of
manpower, time, &
machines
Increase in the in-
process inventory
Failed delivery
dates
Poor workflow
continuity
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4) “Muda” in Transporting
It is Unnecessary movement of parts
between processes caused by unnecessary
transportation distance, temporary
storage, relocations or re-piling up.
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4) “Muda” in Transporting
[Cause]
 Bad facility layout
[Effect ]
 Waste of space
 Production deterioration
 Expansion of
transportation
facilities
 Occurrence of scratches
 Increase production time
 wastes time and energy
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5) “Muda” of Defect-Making

This includes defects, inspections for
defects in-process, and claims,
rescheduling, and resource loss.
federal Tvet agency and EKI 52
5)“Muda” of Defect-Making
[Cause]
Emphasizing on down-
stream processes by
inspection
 Poor in methods and
standards for
inspection
 Lack of standard
operation
[Effect ]
 Increase in material
cost
 Productivity
deterioration
 Increase in personnel &
processes for inspection
 Increase in defects
and claims
 Invite reworking costs
federal Tvet agency and EKI 53
6) “Muda” of Motion
These are non-value adding movements
or more than necessary movements of
workers, equipment, and machines, such
as looking for goods, bending,
stretching, walking, lifting, and reaching
etc.
federal Tvet agency and EKI
Example:
54
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6)“Muda” of Motion
[Cause]
 No education or
training
 No standard
operating
procedure
 Isolated
operation
 Bad facility lay out
[Effect ]
 Increase in
manpower and
processing
 Unstable
operation
 Increases
production time
 Can cause injury
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7) “Muda” in Processing
This consists of processing and operations
primarily unnecessary. It is processing
beyond the standard required by the
customer.
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7)“Muda” in Processing
[Cause]
Lack of analysis of the
contents of operation
 Improper tools and
their use
 Insufficient
standardization
Attitude - ‘Always do it
like this’.
[Effect ]
 Unnecessary
processes or
operation
 Increase in manpower
and man-hour
 Lower workability
 Increase in defects
 Can reduce life of
components
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Benefits of identifying & Eliminating
waste
1. To the company
 Cutting the hidden costs of production.
 Increased customer satisfaction.
2. To Shop floor worker
 Increased job satisfaction:- work with less energy,
work in safe conditions etc.
 Contributing for improvement:-
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5.How to eliminate “Muda”?
1) “Muda” of Overproduction
Produce not more than is needed by
your customers.
you MUST know what your customers
need and use.
Have standardized work or work
instructions for your processes.
federal Tvet agency and EKI 61
5.How to eliminate “Muda”?
2) “Muda” of Inventory
Implement 5S and avoid unnecessary
items
Use just-in-time system
3) “Muda” of Waiting
Proper alignment of work processes,
Consistent machine maintenance (to avoid
machine downtime.)
federal Tvet agency and EKI 62
5.How to eliminate “Muda”?
4) “Muda” in Transporting
Design production lines and materials
flow paths in a way that minimizes the
distances between workstations and
temporary storage sites.
5) “Muda” of Defect-making
Build quality into each process, using
tools like Poka-Yoke, JIDOKA, Andon etc.
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5.How to eliminate “Muda”?
6) “Muda” of Motion
Minimize unnecessary movements
7) “Muda” in Processing
Improving processing efficiency to
achieve the same customer
satisfaction .
 use of low-cost automation, smaller,
and more flexible equipment
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5.How to eliminate “Muda”?
7) “Muda” in Processing(Cntd)
combining steps will greatly reduce
the waste of inappropriate processing.
Look for improvements
Train workers
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Tools for Eliminating “Muda”
1. Andon
2. U-line
3. In-lining
4. Unification
5. Multi-process handling & Multi-skilled
Operators
6. A.B. control (Two-Point Control)
7. Cell production line
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1. Andon
An “Andon” is an indicator informing
team leaders and supervisors of the
current workshop situation with color
boards, flash lights, and automated
announcement.
Tools for Eliminating “Muda”
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Tools for Eliminating “Muda”
1) Calling “Andon”-Used for requesting parts.
2) Warning “Andon” -Used to inform
occurrence of irregularities
on the lines.
3) Progress “Andon” -Used to identify the
progress of operation on the
lines with a short Takt Time.
Types of “Andon”
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2. U-line
A U-line is a layout in which the inlet and
outlet are positioned in the same direction
to avoid walking back for a single operator.
Tools for Eliminating “Muda”
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3. In-lining
In-lining is a way to make the production
lines simple and effective by integrating the
parts processing into the main line in the
unit production.
Tools for Eliminating “Muda”
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Unification of
several
processes
4. Unification
Even if a flowing line
cannot be formed,
odd operations can be
combined together in
a place into an
operator’s work.
Tools for Eliminating “Muda”
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5. Multi-process handling & Multi-skilled
Operators
Multi-process handling means that a single
operator manages multiple machines and
processes in product processing and
assembling. This is the primary factor for
constructing lines by a small number of
operators.
Tools for Eliminating “Muda”
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Tools for Eliminating “Muda”
A multi-skilled worker can deal with
several machines or processes as
described above. The supervisor can
make a flexible placement of operators
when someone within the same team or
section is absent.
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6. A.B. control (Two-Point Control)
A.B. control is a devised automatic control
function. It controls the machine
movement when they come to start or stop
working depending upon the number of
work pieces piled up between the
preceding process and the following
process.
Tools for Eliminating “Muda”
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A.B. control is used
as a tool for time
control to realize
Just in Time(JIT)
Up to Three
6.A.B. control (Two-Point Control)(Cntd)
Tools for Eliminating “Muda”
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7.Cell production line
This is a production line that a single
operator manages all the machining or
assembly operations in unit production.
Tools for Eliminating “Muda”
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7. Cell production line(Cntd)
Advantages
Quality assurance can be ensured.
The production output or efficiency of each
operator can be clarified.
Operators can obtain a feeling of work
achievement.
Tools for Eliminating “Muda”
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To summarize
• The Customer should not pay any price
for cost of wastes that we make.
• Therefore, it is us who have to make our
products better in quality, deliver them
on time and as the same time get more
profit by eliminating MUDA.
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5)Methods for Muda prevention
There are four important methods you can use
for maintaining a waste-free production
environment:
• Standardization
• Visual controls
• Auditory controls
• 5W and 1H Sheet
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Standardization
- Standardization means establishing standard
procedures for every operation so that anyone
can understand and use them – and everyone
does.
Standards must be created, documented, well-
communicated, adehered to, and regularly re-
assessed.
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Contd…….
Standards are required for:
• Machines
• Operations
• Defining normal and abnormal conditions
• Clerical procedures
• Procurement
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Visual and Auditory Controls
• One way waste enters into operations is when
standards are not improved to meet changing
conditions.
• Even standardization fails to sustain waste-
free production if not systematically updated
to take advantage of new materials, new
technology, and worker improvement ideas.
federal Tvet agency and EKI 82
Contd……
• The best way to do this is through visual and
auditory controls.
Red-tagging – Always keep the production floor
free of any thing that is not directly part of the
production process.
Signboards- The purpose of workstations and
the names of the workers who operate them
should be displayed at every processing point.
federal Tvet agency and EKI 83
Contd………..
• Standard quantities should be included on
supply bins or carts. The products produced
on each line or in each cell can be displayed,
and so on.
Outlining- Boarders around tools and
equipment, big and small, help people find
and return things.
federal Tvet agency and EKI 84
Contd....
Andons- Different colored lights can report the
status and needs of a system and signal when
defects or abnormal conditions occur so that
problems can be solved immediately.
Kanban- flexible production instructions or work
orders that trigger materials supply and
production in a pull system, the hallmark of
lean manufacturing.
federal Tvet agency and EKI 85
Contd….
Pitch and Inspection Buzzers - These indicate
when operations get out of sync with demand
or when defects are around.
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The 5W and 1H Sheet
• Five “whys” and one “how”
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Total Preventive Maintenance
• Is one of Kaizen Systems.
• Brings maintenance into focus as a necessary and vitally important part of business.
• is a company-wide system developed to maintain, monitor, and improve all capital
assets of a company.
• It can be considered as the medical science of machines.
• For production it is a system that maximizes equipment effectiveness and
maintains production flow.
cont…
•Maintenance is implemented by all employees in an organization.
•Everyone in the organization from operators to senior
management in equipment improvement.
federal Tvet agency and EKI
Cont…
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federal Tvet agency and EKI
Cont…
Total = All individuals in the organization working together.
Productive = production of goods that meet or exceed customer’s
expectations.
Maintenance = keeping equipment and plant in good condition at
all times.
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federal Tvet agency and EKI
History
• TPM is a Japanese concept.
• Developed in 1951.
• Nippondenso was the 1st
company that implemented TPM in
1960.
• Based on these developments Nippondenso was awarded the
distinguished plant prize for developing and implementing
TPM, by the Japanese Institute of Plant Engineers ( JIPE ).
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TPM Targets
• Reduce manufacturing cost
• Increase production quality.
• Delivery time. Achieve 100% success in delivering the goods
as required by the customer.
• Safety - Maintain accident free environment.
• Moral- Develop multi-skilled & flexible workers.
• Improve OEE (Overall Equipment Effectiveness)
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The Six big Equipment losses
• Equipment failure (Breakdown)
• Set up & adjustment downtime
• Idling & minor stoppages
• Reduced speed
• Process defects
• Reduced yield
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Shift in Attitudes
Operator Maintenance Operator Maintenance
Conventional TPM
I use I maintain &
I fix
We maintain
federal Tvet agency and EKI
Principles of TPM
 Use Overall Equipment Effectiveness (OEE) as a compass for
success.
 Improve existing maintenance systems
 Work toward zero losses
 Providing training to upgrade operations and maintenance
skills
 Involve everyone and utilize cross-functional teamwork
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Types of maintenance
 Breakdown maintenance
Preventive maintenance
*periodic maintenance( time based maintenance)
*Predictive maintenance
 Corrective maintenance
 Maintenance prevention
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Breakdown maintenance
• Repairs or replacements done after the equipment
failure/stoppage or occurrence of severe performance
decline.
• Disadvantages:- unplanned stoppages, excessive damage,
spare parts problems, high repair costs, excessive waiting and
maintenance time and high trouble shooting problems.
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Preventive maintenance
• The primary goal of preventive maintenance is to prevent the
failure of equipment before it actually occurs.
• It relies on the estimated probability that the equipment will
brake down or experience deterioration in performance in the
specified interval.
• It is further divided into -Periodic Maintenance
-Predictive Maintenance
federal Tvet agency and EKI
Long-term benefits of preventive maintenance:
• Improved system reliability.
• Decreased cost of replacement.
• Decreased system downtime.
• Better spares inventory management.
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Periodic maintenance
 Time based maintenance consists of periodically inspecting,
servicing and cleaning equipment and replacing parts to
prevent sudden failure and process problems.
Benefits:
 Extended life and use of the equipment.
 Reliable production at the times when machine is needed
most.
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Predictive maintenance
• predictive maintenance is condition based maintenance.
• This is a method in which the service life of important part is
predicted based on inspection or diagnosis, in order to use the
parts to the limit of their service life.
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Benefits of predictive maintenance
• Increased plant readiness due to greater reliability of the
equipment.
• increase predictive maintenance practices increase the
productivity of equipments.
• Reduced expenditures for spare parts and labor.
• Reduces the probability of a machine experiencing a disastrous
failure, and this results in an improvement in worker safety.
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Corrective maintenance ( 1957 )
 Improvement of equipment so that equipment failure can be
eliminated (improving the reliability) & the equipment can
easily be maintained (improving equipment maintainability).
 Its purposes are- improving equipment reliability
- Safety
- Design weakness( material, shapes)
- Existing equipment undergoes structural
reforms
- To reduce deterioration & failures
(maintenance free eqpt)
federal Tvet agency and EKI
Maintenance prevention (1960 )
• It indicates the design of a new equipment.
• Weakness of current machines are sufficiently studied ( on site
information leading to failure prevention, easier maintenance
and prevents of defects, safety and ease of manufacturing )
and are incorporated before commissioning a new equipment.
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PILLARS OF TPM
1.Autonomous maintains
2.Planned maintains
3. Equipment and process improvement
4.Early management of new equipment
5.process quality management
6.TPM in the office
7.Education and training
8.Saftey and environmental management.
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1 2 3 4 5 6
7
8
106
PILLARS of TPM
federal Tvet agency and EKI
1.Autonomous Maintenance
• Train the operators to close the skill gap between others and
the maintenance staff, making it easier for both to work as one
team.
• There are Seven (7) steps implemented to progressively
increase operators knowledge, participation and responsibility
for the equipment.
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federal Tvet agency and EKI
cont…
1. perform initial cleaning and inspection
2.Countermeasures for the causes and effects of dirt and dust
3.Establish cleaning and lubrication standards
4.Conducting general inspection training
5.Carry out equipment inspection checks
6.workplace management and controls
7.Continious improvement
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2.Equipment and process improvement
Objectives: Maximize efficiency by eliminating waste and
manufacturing loss
• Manufacturing losses are categorized into 12 losses:
 Equipment losses (6)
 Manpower losses (4)
 Material losses (2)
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Equipment losses
110
.
 .
DOWNTIME LOSS
Speed loss
Quality loss
Equipment failure / breakdowns
Set-up / adjustments
Minor stopping
Reduced speed
Process errors
Rework / scrap
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Manpower and material losses
• .
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Manpower losses
Cleaning and checking
Waiting materials
Waiting instructions
Waiting quality confirmation(inspection)
Material losses
Material yield
Energy losses
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3.Planned maintains
Objectives : Establish periodic and predictive maintenance system for
equipment and tooling.
• Natural life cycle of individual machine elements must be achieved
 correct operation
 correct set-up
 cleaning
 lubrication
 feedback and repair of minor defects
 quality spare parts
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4.Early management of new equipments
Objective: : start-up, commissioning and stabilization time for
quality and efficiency
New equipment need to be :
• easy to operate
• easy to clean
• easy to maintain and reliable
• have quick set-up times
• operate at the lowest life cycle cost
113
federal Tvet agency and EKI
5.Process quality management
Objectives: to set and maintain condition to accomplish zero
defect.
Quality rate has direct correlation with
• material condition
• equipment precision
• production methods
• process parameters
114
federal Tvet agency and EKI
6.TPM in office
• Administration and support departments can be seen as
process plans whose principles tasks are to collect, process and
distribute information.
• Process analysis should be applied to streaming information
flow
115
federal Tvet agency and EKI
7.Education and training
TPM is a continuous learning process
 Two major components :
• soft skills training : how to work as a team, diversity
training and communication skills
• Technical training : upgrading problem-solving and
equipment-related skills
116
federal Tvet agency and EKI
8.Safety and environmental management
• Assuring safety and preventing adverse environment impacts
are important priority in the TPM effort.
117
federal Tvet agency and EKI
Overall Equipment Effectiveness
• Objective :to maximize the efficiency of machine or
equipment.
• OEE figures are determined by combining the availability and
performance of your equipment with the quality of parts made
• OEE measures the efficiency of the machine during its loading
time.
• Planned downtime does not affect the OEE figure
118
federal Tvet agency and EKI 119
Overall Equipment Effectiveness (OEE)
• .
Overall Equipment Effectiveness = Availability *performance * Quality yield
Availability = Time available for production -- Downtime
Time available in production
Performance = Ideal cycle time * number of parts produced
Operating time
Quality Yield = total number of parts produced – defect number
Total number of parts produced
federal Tvet agency and EKI 120
Overall Equipment Effectiveness (OEE)
• .
Availability Downtime loss
Performance Speed loss
Quality Yield Quality loss
Overall equipment effectiveness = Availability * performance * Quality yield
federal Tvet agency and EKI
The Six Big Equipment Losses
1. Breakdowns
2. Setups and adjustment
3. Idling and minor stoppages
4. Speed
5. Quality defects and rework
6. Start-up (loss of yield)
121
federal Tvet agency and EKI 122
Overall equipment effectiveness = Availability x Performance rate x Quality rate
(OEE)
Breakdown
Setup and adjustment
Others Idling & minor stoppages
Reduced speed
Quality defects & rework
Start-up yield
federal Tvet agency and EKI 123
Example: OEE Calculation
Item Data
Shift length 8 hrs = 480 min.
Short Breaks 2@ 15 min. = 30 min
Meal Break 1 @ 30 min = 30 min
Down Time 47 min
Ideal Run Time 60 pieces per min
Total Pieces 19,271 pieces
Reject Pieces 423 pieces
federal Tvet agency and EKI 124
Availability =
Operating time
Planned production time
= 373 minutes / 420 minutes
= 0.8881 (88.81%)
federal Tvet agency and EKI 125
Performance =
(Total pieces /Operating time)
Ideal Run Time
= (19,271 pieces/373 minutes)/60 pieces per
minute
= 0.8611 (86.11%)
federal Tvet agency and EKI 126
Quality =
Good Pieces
Total Pieces
= 18,848 / 19,271 pieces
= 0.9780 (97.80 %)
federal Tvet agency and EKI 127
OEE =
Availability X Performance X Quality
= 0.8881 X 0.8611 X 0.9780
= 0.7479 (74.79%)
federal Tvet agency and EKI
Fundamental improvements of TPM
• Increasing motivation: changing people attitudes
• Increasing competency and people skills
• Improving the work environment, so that it supports the
establishment of a program for implementing TPM
128
federal Tvet agency and EKI
TPM Implementation
• .
129
preparation
Announcement to TPM introduction
Introductory education campaign for workforce
TPM promotion
Establish basic TPM policies and goals
Preparation and formulation of a master plan
Kick-off Invite customers, attitude companies and subcontractors
implementation
Develop an equipment management program
Develop a plan maintenance program
Develop a Autonomous maintenance program
Increasing skills of production and maintenance personals
Develop early equipment management program
Standardization Perfect TPM implementation and raise TPM levels
federal Tvet agency and EKI
Announce top management decision to
introduce TPM
• State TPM objectives in a company newsletter
• Place articles on TPM in a company newspaper
130
federal Tvet agency and EKI
Introductory education campaign
• Seminars for managers
• Slide presentation for all employees
131
federal Tvet agency and EKI
TPM Promotion
• Special committees at every level to promote TPM
• Newsletter
• Articles
• Videos
• Posters
132
federal Tvet agency and EKI
Establishing basic TPM policies and goals
• Analyze existing conditions
• Set goals
• Predicting results
133
federal Tvet agency and EKI
Preparation and Formulation of a master plan
• A master plan lays out your goals, what you will do to achieve
them and when you will achieve them
• Detailed plans for each pillar have to be prepared
134
federal Tvet agency and EKI
TPM Kick-off
• The main kick-off to TPM should take the form of a formal
presentation with all the employees attending.
• This opportunity can be used to gain the full support of the
employees.
• Invite external customers, affiliation and subcontracting
companies .
135
federal Tvet agency and EKI
Develop an equipment management program
 The maintenance prevention can be design of new products ,
new machine and existing machines.
 New products: must be easy to produce on new existing
machines
 New machines : must be easy for operation, changeover and
maintenance.
136
federal Tvet agency and EKI
Cont..
 Existing machines: Determine how to eliminate the problem
and reduce maintenance through an equipment design change
or by changing the process
137
federal Tvet agency and EKI
TPM Benefits
• zero equipment-caused defects
• Increased plan capacity
• Increase equipment productivity
• Increase return on investment
• Enhance job satisfaction
• Lower maintenance and production cost
• Reduced equipment downtime
138
federal Tvet agency and EKI
conclusion
• TPM may be the only thing that stands between success and
total failure for some companies.
• It can be adapted to work not only in industrial plants
139
federal Tvet agency and EKI
Any questions…….?
140
federal Tvet agency and EKI 141
THANK YOU

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Muda.pptxgruhxjsidadhidhjzcvifvczghcvjdfgz

  • 2. federal Tvet agency and EKI 2 Contents 1)The concept of MUDA/Waste 2)Methods for categorizing types of Muda 3)MUDA identification 4)Elimination of Muda 5)Methods for Muda prevention 6)TPM concepts and its pillars
  • 3. 3 1) The concept of Muda What is Value? Value is defined by your customer. There are two types of Customers:- -Internal customer -External customer Then Value is the activity/effect what the customer exactly is going to pay for/needs. federal TVET agency and EKI
  • 4. federal Tvet agency and EKI 4 What is Waste/MUDA? • Waste/MUDA is any activity of workers/machines which consumes resources such as money, time, energy, materials, etc without adding value.
  • 5. federal Tvet agency and EKI 5 The main elements of KAIZEN management • Quality (Customer) • Cost (Company) • Delivery(Customer) • QCD is the source of productivity improvement
  • 6. federal Tvet agency and EKI 6 C O S T M I N I M I Z E Better Quality On time Delivery Higher Profit Profit=Price-Cost ምን ይሻላል??? CUSTOMER የትም ፍጭው ዱቄቱን አምጭው Reasonable Price MANUFACTURER
  • 7. federal Tvet agency and EKI 7 The concept of cost Cost minimization • Determination of the sales price of the product Sales price=(manufacturing)cost + profit • Manufacturing cost=(material + labor + facility + utility + others)cost
  • 8. federal Tvet agency and EKI PRICE=COST + PROFIT PROFIT= PRICE - COST Company sets price(Demand>Supply) Market sets price (Demand≤Supply) Traditional Thinking Kaizen Thinking 8
  • 9. federal Tvet agency and EKI 9 The three categories of Operations • Value Adding/Net Operation • Non Value Adding Operation • Muda/Waste
  • 10. federal Tvet agency and EKI 10 The three categories of Operations (1) Net Operation • Part of the operation that adds value to make parts and products Examples, Milling, Turning, Grinding, Assembling and Welding
  • 11. federal Tvet agency and EKI 11 The three categories of Operations (2) Non-Value adding Operations • Operation that adds no value but cannot be avoided Example Setting up, Inspecting, Picking up parts, Removing drill chips
  • 12. federal Tvet agency and EKI 12 The three categories of Operations(Cntd) (3) “Muda” • Muda is a Japanese word meaning Wasteful Activity • Is anything unnecessary in operation. • Can be eliminated immediately
  • 13. federal Tvet agency and EKI 13 The three categories of Operations(Cntd) (3) “Muda” • It increases Production cost • Muda affects the quality of the product and also delivery time
  • 14. federal Tvet agency and EKI 14 Non-value adding and wastes • movements • searching for tools • transporting materials • over production • waiting /idle time • making defects etc Value adding • assembling • molding • spinning • mixing • building • milling etc “Muda” are activities which use resources, time or cost without adding value.
  • 15. federal Tvet agency and EKI Value Chain Consume rs Supplier s Reduce Lead Time Non Value Added & Waste activities 15
  • 16. 16 Product Lead-Time federal Tvet agency and EKI Raw Materials Finished Goods Value Added Time Non- Value Added Time TIME
  • 17. federal Tvet agency and EKI 17 Very Simple Drill • Operation to staple two papers using a stapler when work place is disorganized • Materials and tools –Two pieces of paper –Stapler –Staples
  • 18. federal Tvet agency and EKI 18 Very Simple Drill Result in a disorganized environment N0. Activities Time Type of Operation Measure How 1 Searching for Stapler 35 Sec Muda Eliminate 5S(Set-in-order) 2 Searching for Staples 30 Sec Muda Eliminate 5S(Set-in order) 3 Putting the Staples into the stapler 8 Sec Non-Value adding Minimize Load staples ahead 4 Putting the two papers together 3 Sec Non-Value adding - - 5 Staple the papers 2 sec Net Operation (Value Adding) - -
  • 19. federal Tvet agency and EKI 19 Lessons from the drill • Total time of operation=78 Sec Net Operation(Value adding)=2 Sec(2.6%) Non-Value adding operation=11 Sec(14.1%) Muda(Unnecessary operation)=65Sec(83.3%)
  • 20. federal Tvet agency and EKI 20 MUDA = Anything Unnecessary
  • 21. federal Tvet agency and EKI 21 2)Methods For Categorizing Types of Muda/Wastes Classification of waste A number of methods for classification of waste have emerged. Here are some of them:- The 3MU’s 5M+Q+S The flow of goods The Seven deadly wastes
  • 22. federal Tvet agency and EKI 22 Muda Muri Mura 1) The 3MU’s
  • 23. federal Tvet agency and EKI 23 MUDA-Capacity exceeds load. MURA (imbalance or variation) = capacity sometimes exceeds the load and the load sometimes exceeds capacity. MURI(Physical or mental overburden)- Load exceeds capacity . Productivity improvement does not mean hard work. The Three MU’s
  • 24. federal Tvet agency and EKI 24 The Three M’s Muda • Production factors that increase cost, in other words, all unnecessary things
  • 25. federal Tvet agency and EKI 25
  • 26. federal Tvet agency and EKI 26 The Three M’s (Cntd) Muri • Mental and physical overburden on operators, and overburden on production machinery
  • 27. federal Tvet agency and EKI 27 Muri We should not force hard work on Employees in the name of productivity improvement Value added work Working density = Actual work The Three M’s (Cntd)
  • 28. federal Tvet agency and EKI 28 Muri : overburden
  • 29. federal Tvet agency and EKI 29 የስራ ጫና Muri
  • 30. federal Tvet agency and EKI 30 የስራ ጫና Muri
  • 31. federal Tvet agency and EKI 31 The Three M’s Mura • Variation in work distribution, production capacity of machinery, and material specifications
  • 32. federal Tvet agency and EKI 32 IN OUT
  • 33. federal Tvet agency and EKI 33 Relationship between the 3 M’s • Usually Mura creates Muri which in turn lead to generation of Muda
  • 34. federal Tvet agency and EKI 34 Relationship between the 3 M’s • Therefore, mura creates muri that undercuts previous efforts to eliminate muda. • Eliminating mura is fundamental to the complete elimination of muri and muda
  • 35. federal Tvet agency and EKI 35
  • 36. federal Tvet agency and EKI 36 2) 5M+Q+S • Is another way of thinking in the areas where waste may occurs 5M(man, material,machine, method and management), plus Quality and Safety.
  • 37. federal Tvet agency and EKI 37 Contd… Material Waste of:- Parts, Bolts, Welds, Functions, Storage & Handling. Man/Workers Waste of:- Walking, Waiting, Searching, Unnecessary movements Management Waste of:- Materials, Meetings, Management control, Communications, Vouchers Machine Waste of:- Large machines, General purpose machines, Conveyors, Machines with wasteful movements, Breakdowns, Machine handling
  • 38. federal Tvet agency and EKI 38 Contd…. Method Waste of:- Large lot production, Inventory, Conveyance, Retention, Non standardization, Picking up setting down work pieces.
  • 39. federal Tvet agency and EKI 39 Contd… Quality Waste in:- Making defective goods, Fixing defects, errors, Inspection, Quality control. Safety Waste of:- Disaster prevention methods, Fixing defects.
  • 40. federal Tvet agency and EKI 40 3)The Seven deadly wastes 1) “Muda” of Overproduction 2) “Muda” of Inventory 3) “Muda” of Waiting 4) “Muda” in Transporting 5) “Muda” of Defect-making 6) “Muda” of Motion 7) “Muda” in Processing Cost Reduction by Elimination of muda
  • 41. federal Tvet agency and EKI 41 7 Categories of Waste Defect Making Transportation Over Produced Motion Inventory Over Processed Waiting
  • 42. federal Tvet agency and EKI 1)“Muda” of Overproduction 42 To produce things more than necessary in terms of type, time, and volume. It is called “the worst kind of Muda” since it hides all the other wastes.
  • 43. federal Tvet agency and EKI 43 1)“Muda” of Overproduction [Cause] Excessive work force and facilities Big and fast production machine Lack of customer focus [Effect ] Increase in inventory Outbreak of defects Deterioration of turn- over ratio of funds Advanced preparation of materials and parts Consumes resources Needless wear on machines
  • 44. federal Tvet agency and EKI 44 2) “Muda” of Inventory The situation where items such as raw materials, parts, and finished goods are stagnant or which are not having value added to them. Some are located in the warehouses, and others are in-process inventory.
  • 45. federal Tvet agency and EKI 45 2) “Muda” of Inventory [Cause]  Weak consciousness for inventory Bottle-neck processing stage  Advanced Production  Approximate production  Unreliable suppliers [Effect ]  Waste of space  Needs for inspection, and transportation  Expansion of working fund  Shelf life may expire  It ties up cash  Makes FIFO inventory management more difficult
  • 46. federal Tvet agency and EKI 46 Examples of Inventory Wastes
  • 47. federal Tvet agency and EKI 47 3) “Muda” of Waiting This includes all kinds of waste of time such as workers or parts waiting: -for an upstream process to deliver, -for a machine to finish processing, -for incoming parts or materials, -for process that has a long wait time
  • 48. federal Tvet agency and EKI 48 3) “Muda” of Waiting [Cause]  Bottle-neck processing stage  Bad facility layout  Capacity imbalance  Shortages & unreliable supply chain  Lack of multi-skilling  Poor maintenance. [Effect ] Waste of manpower, time, & machines Increase in the in- process inventory Failed delivery dates Poor workflow continuity
  • 49. federal Tvet agency and EKI 49 4) “Muda” in Transporting It is Unnecessary movement of parts between processes caused by unnecessary transportation distance, temporary storage, relocations or re-piling up.
  • 50. federal Tvet agency and EKI 50 4) “Muda” in Transporting [Cause]  Bad facility layout [Effect ]  Waste of space  Production deterioration  Expansion of transportation facilities  Occurrence of scratches  Increase production time  wastes time and energy
  • 51. federal Tvet agency and EKI 51 5) “Muda” of Defect-Making  This includes defects, inspections for defects in-process, and claims, rescheduling, and resource loss.
  • 52. federal Tvet agency and EKI 52 5)“Muda” of Defect-Making [Cause] Emphasizing on down- stream processes by inspection  Poor in methods and standards for inspection  Lack of standard operation [Effect ]  Increase in material cost  Productivity deterioration  Increase in personnel & processes for inspection  Increase in defects and claims  Invite reworking costs
  • 53. federal Tvet agency and EKI 53 6) “Muda” of Motion These are non-value adding movements or more than necessary movements of workers, equipment, and machines, such as looking for goods, bending, stretching, walking, lifting, and reaching etc.
  • 54. federal Tvet agency and EKI Example: 54
  • 55. federal Tvet agency and EKI 55
  • 56. federal Tvet agency and EKI 56 6)“Muda” of Motion [Cause]  No education or training  No standard operating procedure  Isolated operation  Bad facility lay out [Effect ]  Increase in manpower and processing  Unstable operation  Increases production time  Can cause injury
  • 57. federal Tvet agency and EKI 57 7) “Muda” in Processing This consists of processing and operations primarily unnecessary. It is processing beyond the standard required by the customer.
  • 58. federal Tvet agency and EKI 58 7)“Muda” in Processing [Cause] Lack of analysis of the contents of operation  Improper tools and their use  Insufficient standardization Attitude - ‘Always do it like this’. [Effect ]  Unnecessary processes or operation  Increase in manpower and man-hour  Lower workability  Increase in defects  Can reduce life of components
  • 59. federal Tvet agency and EKI 59 Benefits of identifying & Eliminating waste 1. To the company  Cutting the hidden costs of production.  Increased customer satisfaction. 2. To Shop floor worker  Increased job satisfaction:- work with less energy, work in safe conditions etc.  Contributing for improvement:-
  • 60. federal Tvet agency and EKI 60 5.How to eliminate “Muda”? 1) “Muda” of Overproduction Produce not more than is needed by your customers. you MUST know what your customers need and use. Have standardized work or work instructions for your processes.
  • 61. federal Tvet agency and EKI 61 5.How to eliminate “Muda”? 2) “Muda” of Inventory Implement 5S and avoid unnecessary items Use just-in-time system 3) “Muda” of Waiting Proper alignment of work processes, Consistent machine maintenance (to avoid machine downtime.)
  • 62. federal Tvet agency and EKI 62 5.How to eliminate “Muda”? 4) “Muda” in Transporting Design production lines and materials flow paths in a way that minimizes the distances between workstations and temporary storage sites. 5) “Muda” of Defect-making Build quality into each process, using tools like Poka-Yoke, JIDOKA, Andon etc.
  • 63. federal Tvet agency and EKI 63 5.How to eliminate “Muda”? 6) “Muda” of Motion Minimize unnecessary movements 7) “Muda” in Processing Improving processing efficiency to achieve the same customer satisfaction .  use of low-cost automation, smaller, and more flexible equipment
  • 64. federal Tvet agency and EKI 64 5.How to eliminate “Muda”? 7) “Muda” in Processing(Cntd) combining steps will greatly reduce the waste of inappropriate processing. Look for improvements Train workers
  • 65. federal Tvet agency and EKI 65 Tools for Eliminating “Muda” 1. Andon 2. U-line 3. In-lining 4. Unification 5. Multi-process handling & Multi-skilled Operators 6. A.B. control (Two-Point Control) 7. Cell production line
  • 66. federal Tvet agency and EKI 66 1. Andon An “Andon” is an indicator informing team leaders and supervisors of the current workshop situation with color boards, flash lights, and automated announcement. Tools for Eliminating “Muda”
  • 67. federal Tvet agency and EKI 67 Tools for Eliminating “Muda” 1) Calling “Andon”-Used for requesting parts. 2) Warning “Andon” -Used to inform occurrence of irregularities on the lines. 3) Progress “Andon” -Used to identify the progress of operation on the lines with a short Takt Time. Types of “Andon”
  • 68. federal Tvet agency and EKI 68 2. U-line A U-line is a layout in which the inlet and outlet are positioned in the same direction to avoid walking back for a single operator. Tools for Eliminating “Muda”
  • 69. federal Tvet agency and EKI 69 3. In-lining In-lining is a way to make the production lines simple and effective by integrating the parts processing into the main line in the unit production. Tools for Eliminating “Muda”
  • 70. federal Tvet agency and EKI 70 Unification of several processes 4. Unification Even if a flowing line cannot be formed, odd operations can be combined together in a place into an operator’s work. Tools for Eliminating “Muda”
  • 71. federal Tvet agency and EKI 71 5. Multi-process handling & Multi-skilled Operators Multi-process handling means that a single operator manages multiple machines and processes in product processing and assembling. This is the primary factor for constructing lines by a small number of operators. Tools for Eliminating “Muda”
  • 72. federal Tvet agency and EKI 72 Tools for Eliminating “Muda” A multi-skilled worker can deal with several machines or processes as described above. The supervisor can make a flexible placement of operators when someone within the same team or section is absent.
  • 73. federal Tvet agency and EKI 73 6. A.B. control (Two-Point Control) A.B. control is a devised automatic control function. It controls the machine movement when they come to start or stop working depending upon the number of work pieces piled up between the preceding process and the following process. Tools for Eliminating “Muda”
  • 74. federal Tvet agency and EKI 74 A.B. control is used as a tool for time control to realize Just in Time(JIT) Up to Three 6.A.B. control (Two-Point Control)(Cntd) Tools for Eliminating “Muda”
  • 75. federal Tvet agency and EKI 75 7.Cell production line This is a production line that a single operator manages all the machining or assembly operations in unit production. Tools for Eliminating “Muda”
  • 76. federal Tvet agency and EKI 76 7. Cell production line(Cntd) Advantages Quality assurance can be ensured. The production output or efficiency of each operator can be clarified. Operators can obtain a feeling of work achievement. Tools for Eliminating “Muda”
  • 77. federal Tvet agency and EKI 77 To summarize • The Customer should not pay any price for cost of wastes that we make. • Therefore, it is us who have to make our products better in quality, deliver them on time and as the same time get more profit by eliminating MUDA.
  • 78. federal Tvet agency and EKI 78 5)Methods for Muda prevention There are four important methods you can use for maintaining a waste-free production environment: • Standardization • Visual controls • Auditory controls • 5W and 1H Sheet
  • 79. federal Tvet agency and EKI 79 Standardization - Standardization means establishing standard procedures for every operation so that anyone can understand and use them – and everyone does. Standards must be created, documented, well- communicated, adehered to, and regularly re- assessed.
  • 80. federal Tvet agency and EKI 80 Contd……. Standards are required for: • Machines • Operations • Defining normal and abnormal conditions • Clerical procedures • Procurement
  • 81. federal Tvet agency and EKI 81 Visual and Auditory Controls • One way waste enters into operations is when standards are not improved to meet changing conditions. • Even standardization fails to sustain waste- free production if not systematically updated to take advantage of new materials, new technology, and worker improvement ideas.
  • 82. federal Tvet agency and EKI 82 Contd…… • The best way to do this is through visual and auditory controls. Red-tagging – Always keep the production floor free of any thing that is not directly part of the production process. Signboards- The purpose of workstations and the names of the workers who operate them should be displayed at every processing point.
  • 83. federal Tvet agency and EKI 83 Contd……….. • Standard quantities should be included on supply bins or carts. The products produced on each line or in each cell can be displayed, and so on. Outlining- Boarders around tools and equipment, big and small, help people find and return things.
  • 84. federal Tvet agency and EKI 84 Contd.... Andons- Different colored lights can report the status and needs of a system and signal when defects or abnormal conditions occur so that problems can be solved immediately. Kanban- flexible production instructions or work orders that trigger materials supply and production in a pull system, the hallmark of lean manufacturing.
  • 85. federal Tvet agency and EKI 85 Contd…. Pitch and Inspection Buzzers - These indicate when operations get out of sync with demand or when defects are around.
  • 86. federal Tvet agency and EKI 86 The 5W and 1H Sheet • Five “whys” and one “how”
  • 87. federal Tvet agency and EKI 87 Total Preventive Maintenance • Is one of Kaizen Systems. • Brings maintenance into focus as a necessary and vitally important part of business. • is a company-wide system developed to maintain, monitor, and improve all capital assets of a company. • It can be considered as the medical science of machines. • For production it is a system that maximizes equipment effectiveness and maintains production flow.
  • 88. cont… •Maintenance is implemented by all employees in an organization. •Everyone in the organization from operators to senior management in equipment improvement.
  • 89. federal Tvet agency and EKI Cont… 89
  • 90. federal Tvet agency and EKI Cont… Total = All individuals in the organization working together. Productive = production of goods that meet or exceed customer’s expectations. Maintenance = keeping equipment and plant in good condition at all times. 90
  • 91. federal Tvet agency and EKI History • TPM is a Japanese concept. • Developed in 1951. • Nippondenso was the 1st company that implemented TPM in 1960. • Based on these developments Nippondenso was awarded the distinguished plant prize for developing and implementing TPM, by the Japanese Institute of Plant Engineers ( JIPE ). 91
  • 92. federal Tvet agency and EKI 92 TPM Targets • Reduce manufacturing cost • Increase production quality. • Delivery time. Achieve 100% success in delivering the goods as required by the customer. • Safety - Maintain accident free environment. • Moral- Develop multi-skilled & flexible workers. • Improve OEE (Overall Equipment Effectiveness)
  • 93. federal Tvet agency and EKI 93 The Six big Equipment losses • Equipment failure (Breakdown) • Set up & adjustment downtime • Idling & minor stoppages • Reduced speed • Process defects • Reduced yield
  • 94. federal Tvet agency and EKI 94 Shift in Attitudes Operator Maintenance Operator Maintenance Conventional TPM I use I maintain & I fix We maintain
  • 95. federal Tvet agency and EKI Principles of TPM  Use Overall Equipment Effectiveness (OEE) as a compass for success.  Improve existing maintenance systems  Work toward zero losses  Providing training to upgrade operations and maintenance skills  Involve everyone and utilize cross-functional teamwork 95
  • 96. federal Tvet agency and EKI Types of maintenance  Breakdown maintenance Preventive maintenance *periodic maintenance( time based maintenance) *Predictive maintenance  Corrective maintenance  Maintenance prevention 96
  • 97. federal Tvet agency and EKI 97 Breakdown maintenance • Repairs or replacements done after the equipment failure/stoppage or occurrence of severe performance decline. • Disadvantages:- unplanned stoppages, excessive damage, spare parts problems, high repair costs, excessive waiting and maintenance time and high trouble shooting problems.
  • 98. federal Tvet agency and EKI 98 Preventive maintenance • The primary goal of preventive maintenance is to prevent the failure of equipment before it actually occurs. • It relies on the estimated probability that the equipment will brake down or experience deterioration in performance in the specified interval. • It is further divided into -Periodic Maintenance -Predictive Maintenance
  • 99. federal Tvet agency and EKI Long-term benefits of preventive maintenance: • Improved system reliability. • Decreased cost of replacement. • Decreased system downtime. • Better spares inventory management. 99
  • 100. federal Tvet agency and EKI Periodic maintenance  Time based maintenance consists of periodically inspecting, servicing and cleaning equipment and replacing parts to prevent sudden failure and process problems. Benefits:  Extended life and use of the equipment.  Reliable production at the times when machine is needed most. 100
  • 101. federal Tvet agency and EKI Predictive maintenance • predictive maintenance is condition based maintenance. • This is a method in which the service life of important part is predicted based on inspection or diagnosis, in order to use the parts to the limit of their service life. 101
  • 102. federal Tvet agency and EKI Benefits of predictive maintenance • Increased plant readiness due to greater reliability of the equipment. • increase predictive maintenance practices increase the productivity of equipments. • Reduced expenditures for spare parts and labor. • Reduces the probability of a machine experiencing a disastrous failure, and this results in an improvement in worker safety. 102
  • 103. federal Tvet agency and EKI 103 Corrective maintenance ( 1957 )  Improvement of equipment so that equipment failure can be eliminated (improving the reliability) & the equipment can easily be maintained (improving equipment maintainability).  Its purposes are- improving equipment reliability - Safety - Design weakness( material, shapes) - Existing equipment undergoes structural reforms - To reduce deterioration & failures (maintenance free eqpt)
  • 104. federal Tvet agency and EKI Maintenance prevention (1960 ) • It indicates the design of a new equipment. • Weakness of current machines are sufficiently studied ( on site information leading to failure prevention, easier maintenance and prevents of defects, safety and ease of manufacturing ) and are incorporated before commissioning a new equipment. 104
  • 105. federal Tvet agency and EKI PILLARS OF TPM 1.Autonomous maintains 2.Planned maintains 3. Equipment and process improvement 4.Early management of new equipment 5.process quality management 6.TPM in the office 7.Education and training 8.Saftey and environmental management. 105
  • 106. federal Tvet agency and EKI 1 2 3 4 5 6 7 8 106 PILLARS of TPM
  • 107. federal Tvet agency and EKI 1.Autonomous Maintenance • Train the operators to close the skill gap between others and the maintenance staff, making it easier for both to work as one team. • There are Seven (7) steps implemented to progressively increase operators knowledge, participation and responsibility for the equipment. 107
  • 108. federal Tvet agency and EKI cont… 1. perform initial cleaning and inspection 2.Countermeasures for the causes and effects of dirt and dust 3.Establish cleaning and lubrication standards 4.Conducting general inspection training 5.Carry out equipment inspection checks 6.workplace management and controls 7.Continious improvement 108
  • 109. federal Tvet agency and EKI 2.Equipment and process improvement Objectives: Maximize efficiency by eliminating waste and manufacturing loss • Manufacturing losses are categorized into 12 losses:  Equipment losses (6)  Manpower losses (4)  Material losses (2) 109
  • 110. federal Tvet agency and EKI Equipment losses 110 .  . DOWNTIME LOSS Speed loss Quality loss Equipment failure / breakdowns Set-up / adjustments Minor stopping Reduced speed Process errors Rework / scrap
  • 111. federal Tvet agency and EKI Manpower and material losses • . 111 Manpower losses Cleaning and checking Waiting materials Waiting instructions Waiting quality confirmation(inspection) Material losses Material yield Energy losses
  • 112. federal Tvet agency and EKI 3.Planned maintains Objectives : Establish periodic and predictive maintenance system for equipment and tooling. • Natural life cycle of individual machine elements must be achieved  correct operation  correct set-up  cleaning  lubrication  feedback and repair of minor defects  quality spare parts 112
  • 113. federal Tvet agency and EKI 4.Early management of new equipments Objective: : start-up, commissioning and stabilization time for quality and efficiency New equipment need to be : • easy to operate • easy to clean • easy to maintain and reliable • have quick set-up times • operate at the lowest life cycle cost 113
  • 114. federal Tvet agency and EKI 5.Process quality management Objectives: to set and maintain condition to accomplish zero defect. Quality rate has direct correlation with • material condition • equipment precision • production methods • process parameters 114
  • 115. federal Tvet agency and EKI 6.TPM in office • Administration and support departments can be seen as process plans whose principles tasks are to collect, process and distribute information. • Process analysis should be applied to streaming information flow 115
  • 116. federal Tvet agency and EKI 7.Education and training TPM is a continuous learning process  Two major components : • soft skills training : how to work as a team, diversity training and communication skills • Technical training : upgrading problem-solving and equipment-related skills 116
  • 117. federal Tvet agency and EKI 8.Safety and environmental management • Assuring safety and preventing adverse environment impacts are important priority in the TPM effort. 117
  • 118. federal Tvet agency and EKI Overall Equipment Effectiveness • Objective :to maximize the efficiency of machine or equipment. • OEE figures are determined by combining the availability and performance of your equipment with the quality of parts made • OEE measures the efficiency of the machine during its loading time. • Planned downtime does not affect the OEE figure 118
  • 119. federal Tvet agency and EKI 119 Overall Equipment Effectiveness (OEE) • . Overall Equipment Effectiveness = Availability *performance * Quality yield Availability = Time available for production -- Downtime Time available in production Performance = Ideal cycle time * number of parts produced Operating time Quality Yield = total number of parts produced – defect number Total number of parts produced
  • 120. federal Tvet agency and EKI 120 Overall Equipment Effectiveness (OEE) • . Availability Downtime loss Performance Speed loss Quality Yield Quality loss Overall equipment effectiveness = Availability * performance * Quality yield
  • 121. federal Tvet agency and EKI The Six Big Equipment Losses 1. Breakdowns 2. Setups and adjustment 3. Idling and minor stoppages 4. Speed 5. Quality defects and rework 6. Start-up (loss of yield) 121
  • 122. federal Tvet agency and EKI 122 Overall equipment effectiveness = Availability x Performance rate x Quality rate (OEE) Breakdown Setup and adjustment Others Idling & minor stoppages Reduced speed Quality defects & rework Start-up yield
  • 123. federal Tvet agency and EKI 123 Example: OEE Calculation Item Data Shift length 8 hrs = 480 min. Short Breaks 2@ 15 min. = 30 min Meal Break 1 @ 30 min = 30 min Down Time 47 min Ideal Run Time 60 pieces per min Total Pieces 19,271 pieces Reject Pieces 423 pieces
  • 124. federal Tvet agency and EKI 124 Availability = Operating time Planned production time = 373 minutes / 420 minutes = 0.8881 (88.81%)
  • 125. federal Tvet agency and EKI 125 Performance = (Total pieces /Operating time) Ideal Run Time = (19,271 pieces/373 minutes)/60 pieces per minute = 0.8611 (86.11%)
  • 126. federal Tvet agency and EKI 126 Quality = Good Pieces Total Pieces = 18,848 / 19,271 pieces = 0.9780 (97.80 %)
  • 127. federal Tvet agency and EKI 127 OEE = Availability X Performance X Quality = 0.8881 X 0.8611 X 0.9780 = 0.7479 (74.79%)
  • 128. federal Tvet agency and EKI Fundamental improvements of TPM • Increasing motivation: changing people attitudes • Increasing competency and people skills • Improving the work environment, so that it supports the establishment of a program for implementing TPM 128
  • 129. federal Tvet agency and EKI TPM Implementation • . 129 preparation Announcement to TPM introduction Introductory education campaign for workforce TPM promotion Establish basic TPM policies and goals Preparation and formulation of a master plan Kick-off Invite customers, attitude companies and subcontractors implementation Develop an equipment management program Develop a plan maintenance program Develop a Autonomous maintenance program Increasing skills of production and maintenance personals Develop early equipment management program Standardization Perfect TPM implementation and raise TPM levels
  • 130. federal Tvet agency and EKI Announce top management decision to introduce TPM • State TPM objectives in a company newsletter • Place articles on TPM in a company newspaper 130
  • 131. federal Tvet agency and EKI Introductory education campaign • Seminars for managers • Slide presentation for all employees 131
  • 132. federal Tvet agency and EKI TPM Promotion • Special committees at every level to promote TPM • Newsletter • Articles • Videos • Posters 132
  • 133. federal Tvet agency and EKI Establishing basic TPM policies and goals • Analyze existing conditions • Set goals • Predicting results 133
  • 134. federal Tvet agency and EKI Preparation and Formulation of a master plan • A master plan lays out your goals, what you will do to achieve them and when you will achieve them • Detailed plans for each pillar have to be prepared 134
  • 135. federal Tvet agency and EKI TPM Kick-off • The main kick-off to TPM should take the form of a formal presentation with all the employees attending. • This opportunity can be used to gain the full support of the employees. • Invite external customers, affiliation and subcontracting companies . 135
  • 136. federal Tvet agency and EKI Develop an equipment management program  The maintenance prevention can be design of new products , new machine and existing machines.  New products: must be easy to produce on new existing machines  New machines : must be easy for operation, changeover and maintenance. 136
  • 137. federal Tvet agency and EKI Cont..  Existing machines: Determine how to eliminate the problem and reduce maintenance through an equipment design change or by changing the process 137
  • 138. federal Tvet agency and EKI TPM Benefits • zero equipment-caused defects • Increased plan capacity • Increase equipment productivity • Increase return on investment • Enhance job satisfaction • Lower maintenance and production cost • Reduced equipment downtime 138
  • 139. federal Tvet agency and EKI conclusion • TPM may be the only thing that stands between success and total failure for some companies. • It can be adapted to work not only in industrial plants 139
  • 140. federal Tvet agency and EKI Any questions…….? 140
  • 141. federal Tvet agency and EKI 141 THANK YOU

Editor's Notes

  • #16: Timeline shows duration of non-value-added work. ASK participants where they might get that data from ?? (Timecards, Process Travellers, Value-stream Map) PERFECT Example: Day at Disneyland – wait an hour to ride a 1 minute ride,,, then wait an hour to ride a 90 second ride … etc etc or Post Office, DMV, Bank et al
  • #41: Play “Mudas” video
  • #42: 先ず始めに、造りすぎのムダ。 これは最もやってはいけないムダで、ここに書いてあるように、いろいろな問題、阻害を引き起こします。 <例>□ 例えば、流れの阻害、生産工程というのは造り過ぎると加工がスムーズに流れず、あちこちに仕掛や在庫ができてしまうし、材料や部品の先取りする事になり、結果資金回転率の低下を引き起こし、場合によっては会社が倒産という事にもなりかねません。 造り過ぎる原因としては、過剰人員・過剰設備・大ロット(ダンゴ)生産・ 大きくて速い機械・どんどん造れる仕組み等があります。
  • #54: The brick weighs about five pounds (2.3 kg). How much does the worker actually raise and lower every time he bends over for another brick? This animation illustrates the virtue of videotaping workplace activities. The people who are doing the job may have become accustomed to the waste that is built into the job but, when they watch themselves in the videotape, the waste may become obvious.