3-04 total productive manufacturing

3-04 total productive manufacturing - RCL 3/04 Total...

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TPM RCL 3/04 Total Productive Manufacturing Total Productive Manufacturing (TPM) (TPM) Organizing for Maximum Organizing for Maximum Equipment Productivity Equipment Productivity Robert C. Robert C. Leachman Leachman CSM Program CSM Program University of California at Berkeley University of California at Berkeley March, 2004 March, 2004
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TPM RCL 3/04 TPM Goals TPM Goals Increase overall equipment efficiency (OEE) – Example: Hewlett Packard fab: increase OEE by 33% in 2 years Increase consistency of equipment performance – Example (HP fab): Reduce equipment fails by 95% in 2 years
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TPM RCL 3/04 TPM is Simple and Hard TPM is Simple and Hard TPM is technically simple. Its main feature is a major elevation of all staff’s knowledge, skill and role in improving equipment performance. 80-90% of TPM efforts in the USA fail 50-60% of TPM efforts in Japan fail
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TPM RCL 3/04 Nature of Equipment Failures Nature of Equipment Failures No. of defects or amount of lost production Time Sporadic losses Chronic loss
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TPM RCL 3/04 Nature of Equipment Failures Nature of Equipment Failures Chronic loss (e.g., one wafer breaks out of every 2,000 wafers processed, short-term jams, etc.) – “Normal” losses; typically, losses resulting from the design limits of the machine Sporadic loss (e.g., 12 wafers are ruined because a machine aborted, major failures, etc.) – Typically requires trouble-shooting to restore machine to normal operation
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TPM RCL 3/04 TPM Strategy TPM Strategy Conduct more frequent and thorough inspection and cleaning of machines to discover minor discrepancies before they become failures Enhance PMs to correct minor defects and prevent
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3-04 total productive manufacturing - RCL 3/04 Total...

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