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/ number of sessions – Number of KAIZEN projects – Number of Suggestions TPM – Definition of ?Total? ? Total Effectiveness – Reduction in losses of all equipment to optimize its effectiveness and improve costs ?Total Maintenance – Involves the whole maintenance system inclusive of equipment manufacturer, equipment engineering, and equipment user to improve maintainability ?Total Participation – Everyone has a role to make TPM work – Management to set policy – Middle management, staff to support and lead – Maintenance to maintain and train – Operators to take on new maintenance challenges TPM – Role of Maintenance Function ? Provides technical support for autonomous maintenance done by operators ? Restores deteriorated equipment through checks, inspections, and overhauls ? Identifies Design weaknesses and improves the equipment to errorfree function (via pokayoke) ? Improves technical maintenance skills for checks, inspections, and overhauls TPM – Role of Operator Function ? Maintains basic condition (cleaning and lubrication) ? Maintains proper condition and standards for equipment usage ? Partially restores deterioration ? Basic skill levels in: – Changeover and setup – Reduction of minor stoppages and adjustments TPM – Autonomous Maintenance Definition: ? Operations maintains its own equipment ? Utilize 7step plan* (*Source: Japan Institute of Plant Maintenance) 7 Steps to Autonomous Maintenance Step 1 – Initial cleanup (External) ? “Kickoff” program ? Closely aligned with 6S (5S + 1) ? Management and Staff show mitment ? Clean, Sand and Paint ? Identify sources of defects: – Gauge hidden – Limit switch buried in debris – Crack in Housing 7 Steps to Autonomous Maintenance Step 2 – Stop sources of defects (External) ? Ask ?why ?? five times ? Replace parts with cracks ? Replace worn seals ? Teach Operators how to modify equipment ? Conduct Setup Workshops。 Practice Setups ? Modify Equipment for easier checking and to eliminate sources for debris and contamination – Guards – Chip removal – Acrylic covers to see V belts and moving parts 7 Steps to Autonomous Maintenance Step 3 – Standards Formulation ? Standards for cleanup and ch