General Master Plan v4 (English)

T:/ Plans_Assets/Site/TPMplans/TPM Site Masterplan Jan 2001.
xls
Colonization
Thru
Cooperation
P Activities
o
l
i
c
e
Work Structure
a Definition
n
d
S
t
Audit & Self
r
Assessment
a
t
Consultant Visits
e
g
y 5S & LOTO
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T:/ Plans_Assets/Site/TPMplans/TPM Site Masterplan Jan 2001.xls
Autonomous Maintenance
Focused
Improvement

Planned
Maintenance
Training
Education

Education
Early Management
Quality
Maintenance

Quality
Maintenance
Office
SHE

SHE

Colonization
Thru
Cooperation
Awareness Foundation
Activities 1st - Year

1ºQ 2ºQ 3ºQ 4ºQ
a. Hold Health Check Exercise
b. TPM Announcement
c. Establish TPM Promotion Organization
d. Establish TPM Policy and Objectives
e. Define work structure and Governance (Pillar champions and members)
h. TPM Basic training for key people
f. Implement a downtime data collection system
k. Set up Top Level KPIs aligned with SIA and cascade down to the Pillars
g. Define a Pilot Line and Continuous Improvement Cases
i. Develop basic AM activities at the Pilot Line and Kaizens
j. Prepare a TPM Master Plan
l.TPM Kick Off
a. Self Assessment ( Internal )
b. Self Assessment ( MET )
c. Pre - Audit ( JIPM )
d. Final Audit (JIPM )
a. JIPM Consultant
b. Others
a. Implement 5S process
b. Implement LOTO process
c. Prepare Action Plan for Self Assessment
d. Prepare Action plan for Consultant Report ( JIPM )
a. Define Pillar Work Structure

b. Define Pillar Vison and Mission

c. Define Pillar KPIs
d. Prepare Pillar Master Plan
e. Provide Training to AM Pillar Members ( pillar methodology and tolls )
f. Implement 5S Process in Production Areas
g. Pilot Line ( AM Steps )
h. Others Line ( AM Steps )
i. Process Area and Utilities Areas ( AM Steps )
j. Prepare Action Plan for Self Assessment
k. Prepare Action Plan for Consultant Report ( JIPM )
e. Provide Training to FI Pillar Members ( pillar methodology and tools )
f. Implement Data Collection System
g. Implement OEE and Loss Tree ( 16 biggest losses )
h. Implement OEE Loss Tree Management Process
i. Define and implement Visual Control Process ( activities boards, static and dynamic visual controls )
j. Implement Improvement Record Process ( MP Sheets )
k. Implement Advanced Problem Solving Tools ( QC Story, Infinite Looping, PM Analysis )
l. Identify biggest losses and improvements cases to be developed using Basic and Advanced TPM Tools
m. Develop and implement Process for Kaizen Management ( 4.15 )
n. Define Zero Concepts and Control this data information
o. Implement Cost Loss Tree Process
p. Define Non Stop Line
q. Define Priority Team Process
r. Prepare Action Plan for Self Assessment
s. Prepare Action Plan for Consultant Report ( JIPM )


e. Provide Training to PM Pillar Members ( pillar methodology and tolls )
f. Develop Control System to Manage Maintenance Information
g. Develop Control System to Manage the F-Tags
h. Define a Maintenance Strategy and Equipment Classification
i. Implement Breakdown Analyzes and Recurrence Breakdown Matrix
j. Define and Implement Pannned Maintenance Based on Time ( TBM )
k. Define and Implement Planned Maintenance Based on Condition ( CBM )
l. Implement Lubrication Pan
m. Develop and Implement Calibration Plan
n. Develop Ativities to Increase MTBF
o. Develop Activities to Decrease MTTR
p. Develop and Implement Activities for Transfering skills from PM to AM
q. Develop and Implement Process to Reduce Repetitives Breakdown ( process to achieve Zero Breakdown )
r. Develop and Implement RCM System
s. Develop and Implement Manitenance Budget and Cost Loss Tree Process
t. Develop Process to Control and Optimize Spare Parts
u. Prepare Action Plan for Self Assessment
v. Prepare Action plan for Consultant Report ( JIPM )
e. Provide Training to T&E Pillar Members ( pillar methodology and tools )
f. Define and Comunicate the T&E Policy and Strategy
g. Implement OPL Program
h. Implement Skill Matrix Process ( operators )
i. Implement Skill Matrix Process ( maintenance area )
j. Implement Skill Matrix Process ( administrative area )
k. Implement Training Plan

l. Establish Evaluation for Training Process

m. Implement Recognition Program
n. Prepare Action Plan for Self Assessment
o. Prepare Action Plan for Consultant Report ( JIPM )
c. Define Pillar KPI's
e. Provide Training to EM Pillar Members ( pillar methodology and tools )
f. Provide Training about Project Tools ( Hazops, FMEA, PHA, LCC, Value Engineering )
g. Define EEM process ( criteria to small and big projects )
h. Define and Implement EEM Pilot Project
i. Roll out EEM methodolgy for All Project
j. Develop MP Information Process and System
k .Use the "S" curve to manage expends and time of implementation for key projects
l. Develop Project Loss Tree
m. Implement LCC process
n. Provide basic TPM training to Key suppliers
o. Prepare Action Plan for Self Assessment
p. Prepare Action plan for Consultant Report ( JIPM )
e. Provide Training to QM Pillar Members ( pillar methodology and tools )
f. Define and Comunicate the Quality Policy and Strategy
g. Implement Quality Loss Tree
h. Develop a quality improvement cases based on Quality Loss Tree
i. Introductory Training - Infinite Looping
j. Implement QA Matrix for Pilot Line
k. Implement QM Matrix for Pilot Line

l. Implement Q Points on Pilot Line

m. Roll out QA, QM Matrix and Q-Points for Othes Lines
n. Establish a methodology to capture Zero Defects
o. Establish Process to Identify and Implement Poka Yoke to Avoide Quality Issues
p. Implemente Q Points simplification and be automated Process
q. Develop Improvement cases to reduce the losses: Measurement and Adjustment / Defects and Rework
r. Implement Process to Reduce Material Defects from Suppliers
s. Develop improvement cases to improve CP/CPK
t.Training people in Statistical Control Process
u. Prepare Action Plan for Self Assessment
v. Prepare Action plan for Consultant Report ( JIPM )
e. Provide Training to Office Pillar Members ( pillar methodology and tools )
f. Define Pilot for Administrative Area and Implement 5S
g. Develop Plan to Roll Out 5S to Others Administratives Area ( step 1 )
h. Develop and Implement 5S Audit Process
i. Define Pilot Administrative Area to Implement Office in Software ( steps 2 ot 5 )
j. Define Plan to Roll Out Officce in Software ( steps 2 to 5 )
k. Develop and Implement Office Audit Process in Administratives Areas ( steps 6 and 7 )
l. Prepare Action Plan for Self Assessment
m. Prepare Action Plan for Consultant Report ( JIPM )
a. Define Pillar Work Strucutre
e. Provide Training to SHE Pillar Members ( pillar methodology and tools )
f. Define and Comunicate the SHE Policy and Strategy
g. Implement Process to Manage SHE Tags

h. Implement SHE Loss Tree

i. Develop a SHE improvement cases process based in SHE Loss Tree and BBS Program
j. Implement BBS program
k.Train operators in Risk Analyze for Safety and Environment
l. Implement S-Point Process on Pilot Line
l. Implement S-Point Process for O thers Lines
m. Implement 3 Rs Methodology
n. Implement SHE Management System ( OSHAS )
o Establish Prcess to Identify and Implement Poka Yoke to Avoide Accident
p. Prepare Action Plan for Self Assessment
q. Prepare Action plan for Consultant Report ( JIPM )

Master Plan - Factory

Foundation Preparetion Implementation Sustain
2nd - Year 3rd - Year 4th - Year 5th Year 6th Year
1ºQ 2ºQ 3ºQ 4ºQ 1ºQ 2ºQ 3ºQ 4ºQ 1ºQ 2ºQ 3ºQ 4ºQ 1ºQ 2ºQ 3ºQ 4ºQ 1ºQ 2ºQ

Step 1 Step 2 Step 3 Step 4 Step 5 Step 6

Step 1 Step 2 Step 3 Step 4
Step 1 Step 2 Step 3 Step 4





Growth and Innovation
6th Year 7th Year 8th Year 9th Year 10th Year
3ºQ 4ºQ 1ºQ 2ºQ 3ºQ 4ºQ 1ºQ 2ºQ 3ºQ 4ºQ 1ºQ 2ºQ 3ºQ 4ºQ 1ºQ 2ºQ 3ºQ 4ºQ

Step 7
Step 5 Step 6 Step 7
Step 5 Step 6 Step 7









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T:/ Plans_Assets/Site/TPMplans/TPM Site Masterplan Jan 2001.

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Activities 1st - Year

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b. Define Pillar Vison and Mission

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c. Define Pillar KPIs

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l. Establish Evaluation for Training Process

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l. Implement Q Points on Pilot Line

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h. Implement SHE Loss Tree

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Master Plan - Factory

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Step 1 Step 2 Step 3 Step 4 Step 5 Step 6

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Growth and Innovation

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