TPM Kaizen

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NONPROPRIETARYDOCUMENT

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Finishing TPM Kaizen

Clean Sweeps

Hayes Lemmerz International, Inc.

Gainesville Operations

Nonproprietary


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Describe the ProblemDescribe the Problem11

Team Champion / Sponsor: Rafael AlvarezApprovals:Team Leader: Jeff Routzahn

Actual Completion Date:Expected Completion Date: 3-22-07

Output Boundary: Final InspectionInput Boundary: Machining

Metrics: % TPMs Completed for pretreatment, primer, liquid and clear coat systems.

Team Objectives: The objective of this team will be to analyze each TPM to verify that it is a value added TPM, write-up a description of

this TPM, how often this TPM must be completed, the time required to complete each TPM, what PPE is required to be worn, and to reviewfor other TPMs that might be value added but have not yet identified. Compliance to TPMs schedule is 100% obtainable each and everyweek.

Problem Statement: The finishing area has many production related TPMs set-up for maintaining equipment, dumping tanks, and generalcleaning of the paint system. Adherence to this program has been very difficult to maintain and the TPMs that are required have not beencompletely documented as to what needs done, how to do it, and the time required to do each TPM. We also have no operating

instructions that spell out what clothing should be worn during Paint Tech TPMs and system cleaning TPMs. When TPMs are notcompleted, rework and scrap increase for dirt and paint application issues, including paint drips, heavy clear and primer, etc. PMcompliance has averaged 46% in the last 4 weeks since we began painting again on 3 rd shift.

Customers: Final Inspection

Team Members: Samantha Turner, Dustin White, Gustavo #1 Menchacu, Bob Ribbit Kohler, and Lan Nguyen.

Project Start Date: 3-21-07Team Name: Clean Sweeps


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Describe the ProblemDescribe the Problem11

A systematic approach utilizing all employees through the

implementation of team based activities to achieve maximumequipment effectiveness by reducing operating costs.Goals of TPM:Zero accidentsZero defectsZero breakdowns

TPM

TOTAL PRODUCTIVE MAINTENANCE


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Analyze Historic Results/Analyze Historic Results/

Map Current ProcessMap Current Process22

TOTAL TPM

05

10

15

20

25

30

35

40

45

12-Feb 19-Feb 26-Feb 5-Mar 12-Mar

Due Complete


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Map Current ProcessMap Current Process22PRETREAT TPM

0

2

4

6

8

10

12


Due Complete

PRIMER TPM

0

2

4

6

8

10

12


Due Complete


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CLEARCOAT TPM

0

2

4

6

8

10

12

14


Due Complete

LIQUID TPM

0

1

2

3

4

5

6

7

8

9


Due Complete


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Identify & Prioritize Waste

33

Check Marks = CompletedCircled = Not Completed


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Evaluate Root Cause/

Identify Improvement Needs44

TPM not

Completed

on Time

Environment Methods

Material

Machines

Personnel

Lack of ownership by areas

Lack of priorities

Manning shortages

Unplanned downtime

Constant Machine breakdowns

Lack of tools to per form PMs

Not clear dir ection whenfacing a downtime situation

Weekly tasks confused withdai ly tasks

Lack of clear instructions

Lack of planning

High production demand

Firefigthing instead ofpreventing

Dirty environment

TPM FINISH - KAIZEN


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Document Activities/

Containment55

AA

3-27-07RoutzahnRevise Weekly PM List

3-23-07Ribbit, Samantha, JeffTPM procedures for Clear

3-23-07Ribbit, Samantha, JeffTPM procedures for Liquid

3-22-07Ribbit, Samantha, JeffTPM procedures for Primer

3-23-07Lan, Gustova, DustinTPM procedures for Pretreatment

3-22-07TeamReview and write TPM procedures

3-22-07TeamReview present paint TPMs

3-21-07RoutzahnWrite Charter for team

WhenWhoWhat


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Identify Countermeasures

55BB

3-28TurnerInstruct operators3-26RoutzahnPost new instructions in correct areas

3-26RoutzahnPost revised Weekly TPM Sheet


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Review PerformanceReview Performance

66

PM completion will be tracked on a monthly basis.


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TPM Kaizen

Documents

Transcript of TPM Kaizen