Smart Maintenance Maintenance as a strategic success factor THROUGH THE UNIQUE HARTMANN TPEM PROCESS World Class Manufacturing Conference Ljubljana March 16 th, 2017
Yvonne Hartmann President & CEO Eric Hoffmann Vice President, Europe International TPM Institute, Inc. 4018 Letort Lane Allison Park, PA 15101 USA Tel: +1 412 486 6340 Fax: +1 412 486 6375 www.tpm-institute.com
About International TPM Institute The International TPM Institute, Inc. has consulted around the world since 1990, with many Fortune 500 clients, and companies across a variety of industries. We have experience with a wide range of plant sizes and project scopes - from 50 employees to 15,000, and from several months to several years. One of our longest TPM installations was a 6 year project that concluded with the plant receiving the coveted TPM Award in 2001. Based on the success of this installation, Daimler Chrysler incorporated TPM as a mandatory part of its DC Production System. Swiss American founder of International TPM Institute, Inc., Edward H. Hartmann, P.E., has been called the Father of TPM in the United States and TPM Pope in Germany. Mr. Hartmann was the first to adapt, introduce and successfully install TPM in plants in the US, Canada, Mexico, South America, across Europe and Southeast Asia. In order to make the system accessible to Western manufacturers, he developed a state of the art approach to installing TPM in the Western world, called TPEM and is the author of the best selling book, Successfully Installing TPM in a Non Japanese Plant." TPEM is practiced by all TPM Institute consultants, and the approach has led to a typical 70% productivity improvement, over 400% ROI and the loyalty of clients such as Mercedes, Conti Tire, Michelin, Kellogg s, Abbott Labs, as well as an unparalleled track record for successful TPM installations across North America, South America, South East Asia and Europe. Our multilingual consultants work with clients around the world. International TPM Institute offers audits, TPM Awards and created the widely recognized TPM Plant of the Year award. With our team of consultants in Europe and North America, we have installed our TPEM, Hartmann Method in over 250 different companies worldwide with great success.
Biographical Sketch Eric Hoffmann, Dipl. Ing. is currently a Senior Consultant and Vice President of the International TPM Institute in Europe. His consulting focuses on maintenance management and TPEM covering a range of industries including automotive, automotive suppliers, electronics, plastic, glass, pulp, paper, metals, process industries, food, and general manufacturing. He graduated in mechanical engineering at ETH Zurich in the early 1980s and went on to work as a plant manager of a corrugated cardboard production company before joining International TPM Institute. During this time, he himself introduced TPM at the plant, and became well aware of the challenges and opportunities of TPM. Mr. Hoffmann has personally implemented over 50 installations in more than 10 countries and has decades of manufacturing, industrial, and maintenance engineering experience. He has been involved in continuing improvement initiatives for manufacturing, maintenance, and non-manufacturing environments. His responsibilities focused on providing sound TPEM utilizing PM and PdM processes and procedures to improve equipment performance, quality, and reliability to reduce unplanned downtime and reduce both direct and indirect manufacturing costs. He holds yearly public and in-house TPM seminars, primarily in German, but has also given them in French and English.
Content Smart Maintenance Cloud based Technology for Maintenance Maintenance Strategy Success factors 5
Industry 4.0 Merges state of the art information & communication technologies with classic production and logistics processes Products become more and more individualized Life cycles of products get shorter Uses possibilities of real and virtual world called cyberphysical production systems (CPPSs) Creates a great amount of artificial intelligence through program, storage, sensor and communication capacities 6
Cloud-based Application Application of Internet Technology for faster Communication between Humans, Machines and the resulting Products Human CLOUD Product Machine 7
Machinery and the Cloud CNC Order Program Drawing Training Machine 4.0 5S EM PM SMED 8
Imagine a Smart Factory employee using Industry 4.0 to improve TPM efficiency Your employee receives an order for a specific machine and >> Access to information related to equipment health and required maintenance activities is more precise and immediate = near zero downtime Your employee works in a TPM Team independently and quickly, often with handheld devices Your employee instantly accesses knowledge that is stored and shared through virtual encyclopedias developed in house 9
And Your employee receives an order for a specific machine >> Your employee s collaboration between production and maintenance departments is simplified with real time shared information for set up, repair, or alterations Maintenance strategies can be reviewed quickly based on compiled operation data, condition monitoring and equipment history 10
Equipment Management TPM Total Productive Maintenance TPEM Total Productive Equipment Management 11
Running machines to TOP productivity Teamwork Workplace design TPM-5 S Productivity & Quality TPM-Equipment Management Maintenance and Cleaning TPM-Preventive Maintenance Set up time reduction TPM-SMED 12
Smart Maintenance Smart because of >> Diagnostic tools for machine reliability with adequate sensors for pressure, temperature, vibration etc.. Real time monitoring of all machine data Expert solutions available by the machine manufacturer Online support for maintenance Various other smart success factors 13
Cloud based Maintenance Success monitoring Data recording with sensors Cloud based Maintenance Team Analysis Data monitoring 14
Maintenance for success Machines need Preventive Maintenance! Task lists and Schedules for Preventive Maintenance Maintenance is an important part of Production Production and Maintenance operate together as a team Production goes for Autonomous Maintenance Maintenance not only on weekends! Support from Planning Department is needed 15
Preventive Maintenance From Low-Tech to High-Tech Approach by Edward Hartmann Add High Tech work: Equipment: Improvements Overhaul Monitoring Major PM, including Predictive Maintenance New Equipment Design Training of operators High-Tech Work Maintenance Department Routine work 20-30% Delegate routine work to operators (after training) Equipment: Cleaning Adjusting Lubrication Set-up Inspection (most) Minor repairs (some) Etc.. 16
TPEM Hartmann Method Implement TPM starting with a feasibility study Get to know your own TPM potential in your plant Success is the best motivator Work out your quick TPM wins Go for a strong implementation of your action plan TPM Audits from the International TPM Institute provide a successful path towards the renowned TPM AWARD 17
Roadmap towards the TPM AWARD 27-36 Months TPM Award TPM Certification Automatically when all the cost centers and departments are certified Per department or cost center (TPM is installed, successfully implemented and results are achieved) 15-24 Months Audit Level II TPM-Expansion TPM EM, TPM PM, TPM SMED, TPM AM, level II audit (Progress Audit), TPM is self sustaining 6-12 Months Audit Level I 2 Months Pilot Implementation Feasibility Study Basic cleaning and maintenance (if necessary) develop TPM EM and TPM PM, introduction of 5S, Audit level 1 (Introductory Audit) OEE / ECA, maintenance, skills, order / cleanliness, factory culture, planning of pilot launch, management presentation Introduction and Training Factory Audit & TPM management presentation, TPM training, TPM Feasibility Study Training
TPM AWARD 2016 odelo Slovenija d.o.o. Prebold Slovenija AWARD has successfully introduced TPM in all areas North America Pittsburgh, USA South America Santiago, Chile Europe Zurich, Switzerland Yvonne Hartmann, President ITPMI Certification Authority Prebold, December 2, 2016 Asia/Pacific Singapore