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Kaizen Methodology |
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Tel:+86(0)755 22352797
Fax:+86(0)755 22352797
E-mail:ck@ckaizen.com
Web:http://www.ckaizen.com
Add: |
2F, Block A, Oastar Building, Zhongkang Road, Shangmeilin, Futian District, Shenzhen City, Guangdong Province, China
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1.TPM Management Philosophy Productivity of any enterprise inputs and outputs are measured. Output of products (services, information) input is greater than 3M (materials, people, equipment), production can have practical significance. That is, to improve productivity, one way to spend money on equipment investment; method II is not to spend money or less money, by people, machinery, methods of TPM activities are fully coordinated. From this description, TPM is the coordination of technical and material products. Through the equipment, operational improvements, to promote rational thinking people change, especially in the promotion of employees to form a sense of ownership in order to bring competition to the vitality of enterprises. 2.TPM implementation of the principle
(1) Adhere to the voluntary self-regulation
TPM group activities are voluntary participation in the business intelligence and information exchanges, co-improved, and seek to solve the problem of group activities and self-discipline. If only part of the activities of a small number of people in order to meet the diagnosis or to carry out some surprise, then, TPM is not successful. TPM is a step-by-step activity of the STEP. As managers, we must arrange the time, indicating the direction of activities to give sufficient attention and strong support. For the group behind to give special guidance. (2) Adhere to the practice
TPM is a thoroughly practical activity should not be so anxious to improve. If you omit the process, only the results of great importance, then on at the scene and to comply with the basic principles will cease to exist. Organize, straighten out the clean-up activities to the habit of 3S, maintaining the rules of good clean work site, and to comply with the dynamic development of the standards, the timely discovery and recovery, to improve the unreasonable. (3) Continuing kaizen business TPM so that the business is now easier, more convenient, more efficient, more secure manner. TPM improvement in business activities, the group should reflect the different characteristics and values, a clear purpose. Improvements, changes must be reflected in the standard management of projects, do a good job and standard TPM management interface. (4) Clear objectives at all stages Correctly grasp the current standard, to the best state the goal of a decision to carry out its activities, the best is the objective of zero defects, the various stages of the goal to be able to reflect the increase in step-by-step differences. (5) The development of individuals and organizations People-centered to the TPM activities. Everyone has the potential to stimulate the potential of each individual group activities, to maximize everyone's enthusiasm, miracles can be created.
3.TPM implementation steps
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Distinction
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Step |
Implementation of key |
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The preparation phase |
1. The highest decision-makers are determined to declare the import TPM |
·Declaration of the company, and published in internal publications, or bulletin board |
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2. TPM's education and activities |
·Carried out in accordance with other walks of life into the concept of education TPM |
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3. TPM to promote the establishment of the rank system with superimposed small group |
·Promote the establishment of commissions, the specialized division, the Service Bureau and the system ranks a small group |
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4. TPM basic set of objectives and targets |
·Reference point is the status of data collection and target setting ·Predictor for the effect setting |
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5. TPM planning to start the Master Plan |
· Prepared from the Introduction to fully implement
·Period of about 3 to 5 years |
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Began to import |
6.Kick off meeting |
·Full participation and invite third-party plant, relations between the enterprises to participate in |
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The implementation phase |
7. The establishment of production efficiency of the system 7.1 individual improvement 7.2 self-preservation 7.3 preservation plan 7.4 Education and training |
·The project team to improve the activities of small groups and on-site · Step up these methods and the diagnosis ·Improved security, the prevention of preservation, preservation predict ·Sub-long focus on education and education for members to convey · Maintenance of skills upgrading training ·Be able to work More / multi-function training |
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8. The establishment of new products, the development of new equipment management system |
·Products set up easily and easy to use development and management of equipment |
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9. The establishment of the quality of preservation of the system |
·Good conditions for setting and maintaining management
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10. Indirectly, the affairs of the establishment of departments of system efficiency |
·Support the production efficiency of various departments and improve the services of Loss |
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11. The establishment of safety, health and the environment management system |
·Disasters, the establishment of zero, zero-pollution system
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The confirming phase
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12. Full implementation of TPM to enhance the level |
·P, Q, C, D, S, M reached |
Special Description: (1) In the import fully prepared by the preparatory period, the beginning of the implementation of import TPM. According to enterprises of different sizes are different from the first phase of the enterprise ① diagnosis at the scene to prepare the first phase of the preparatory period ③ complete, it normally takes 1 ~ 3 months. If the TPM has been carried out business activities, you can then enter into the implementation period, this phase usually takes 2-3 months. After entering the implementation phase, will be officially launched here STEP stage of TPM activities, the enterprise activity of small organizations will also be reflected in the focus here. This stage to spend the longest time, it normally takes 2-3 years to be implemented, and large enterprise groups sometimes need more than 3 years or even 5 years, such as South Korea's Samsung TPM import since 1988, it has been 15 years, have never stopped implementation. The first time in the sublimation phase of TPM ⒂ sublimation, will launch a challenge to the activities of 0 defects. (2) Listed above two different sets of procedures are based on the state of the business can have a choice, in 15 stages, the first ① ② with the first stage, we can change the order, the first stage of ② and ④ can also be combined, and the first ⑦ -- ⒁ stage of the 8 pillars of TPM activities, is due to the characteristics of enterprises and promoting the level of innovation in the trade-off after 3 or 5 pillars of the pillars of the form, and is also entirely possible, and therefore do not have a fixed implementation of TPM is almost a model. Finally would like to stress that all activities must be built on the basis of 5S. 4.TPM fundamental to the successful implementation First, the highest level of participation It can be said that the implementation of TPM is to improve the physique and the hard work equipment. Having said that, but still have the active participation of high-level success of the first element. Second, promotion of human resources departments and have the highest level of support. Decided to implement the policy of promoting the establishment of departments, to raise up strength with outstanding talent. All departments must recognize the need for TPM activities, the highest level of accepted ideas, to reach a consensus between the implementation of the. Third, the preparation before the start In accordance with the scale or production plant, select the appropriate equipment type as the model line, the equipment should be an important election and that the larger the level of start-effective production facilities.
Fourth, the beginning and implementation
The highest level by the supervisor or director to lead all members to participate in the following session initiation (Kick off meeting) the declaration that the determination to promote TPM. And activities to be posted on the company banners, set up billboards, and to attract the full participation and set out the basic principle of the company, objectives, quantitative indicators. 5. TPM evaluation Include: general management and P (Productivity), Q (Quality), C (Cost), D (Delivery), S (Safety), M (Morale) and so on.
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Categories
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No. |
Project Name |
Formula |
Evaluation
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Units |
During
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General management
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1 |
Turnover |
-- |
Millions |
Year |
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2 |
Profit |
-- |
-- |
-- |
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3 |
Value-added productivity |
After-tax net profit Number of employees company-wide |
Millions |
Year |
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P |
4 |
Labor productivity |
Turnover Labor in the total number of hours of work |
Yuan/hour |
Year / month |
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5 |
OEE |
Jia-time dynamic rate (load time - stop time) Load time × performance Jia moving rate (yield × baseline C.T.) Load time - stop time × yield (yield few) Production -- |
% |
Year / month |
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6 |
The number of sudden failure |
Factory in accordance with the actual occurrence of the number of machines cumulative |
Pieces |
Month |
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7 |
MTBF |
The total operating hours The number of downtime |
Hour |
Year / month |
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8 |
MTTR |
Total downtime The number of downtime |
Minute |
Year / month |
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9 |
The number of the short stop |
The number of record of less than 5 minutes (or 10 minutes) down |
Times |
Year / month |
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Q |
10 |
The rate of the bad process |
The number of heavy goods + bad + scrapped goods production |
% |
Year / month |
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11 |
Customers complain |
Record the actual number of customers complain |
Pieces |
Year / month |
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C |
12 |
Maintenance costs |
The cost of materials + outsourcing + internal labor costs |
Ten thousand |
Year / month |
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13 |
TPM activities of the investment cost |
Internal labor cost + consultants costs + training costs + production costs |
Millions |
Year |
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14 |
Kaizen income |
Total kaizen income - input costs |
Millions |
Year |
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D |
15 |
Production lead time |
The average number of days from accepting orders to shipments |
Days |
Year / month |
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16 |
Lag suspended products |
Statistical cut-off of finished products per month, semi-finished products and materials inventories |
Pieces / month
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Month |
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S |
17 |
The number of significant harm |
Statistics on the number of actual |
Pieces |
Year / month |
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18 |
The number of minor injuries |
Statistics on the number of actual |
Pieces |
Year / month |
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M |
19 |
The number of kaizen proposals |
Improvement to the total number of cases Number of employees |
Pieces / person
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Month |
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20 |
Training be able to work more |
As much as the actual training to workers through the test |
person |
Year |
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21 |
Small group meetings |
Statistics The number of meetings per month for each small group |
Times / group / month |
Month |
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