4. 1. Declaration by top Management.
2. Awareness & Training (5S & Pilot on Model Machines)
3. Formation of TPM Organization / Promotion team / Logo
4. Setting basic TPM targets.
5. Create TPM Master plan.
TPM Preparation Phase Steps
5. • TPM Steering Committee Monthly Review Meeting.
• Regular Site Reviews to the People & Equipment.
• Demanding the Results.
TPM Declaration by Top Management & Their Commitment
7. RTG#37
EH#08
TT#107
QC SPR #26
RS#05
QC#09
Selected Managers Model Machines for TPM Preparation Phase:
About 70 individuals combined from
Engineering , Operation & HSE were
selected to manage and lead Manager
Model Machines.
Awareness & Training ( 5S and MMM)
8. 1st
Nov 12
2nd
March 13
3rd
July 13
4th
Aug 13
Kick off
17th Sept 13
Performance
• Complete Step 0
• Start Step 1
• Complete Step 1
• Start Step 2
• Complete Step 2
• Start step 3
• Complete Step 3
• Step 3, 4 & 5 of
Preparation Phase
TPM Preparation Phase Workshops
14. TPM Kick Off on 17th of Sept 2013
14
MMM Leaders
Ahmed Akaak, Acting
CEO Incense Ignition by SMT Abdul Wadood,
TPM Consultant
Erik Sasz, GM CT Operation
Naif Al-Awaid,
GM Shared Service Centre
Amr Khalifa,
GM Tech Asset Management, AME
APMT Region
Musallam Tabook,
Labor Union Chairman
15. TPM Kick Off on 17th of Sept 2013
15
Manger Model Machines Exhibition in Site
16. TPM preparation phase .
TPM Kickoff .
TPM progress in first phase .
Results .
Content
19. Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar
1
1.1
1.2
1.3
1.4
2
2.1
2.2
2.3
2.4 Shift 4
3
3.1
3.2
3.3
3.4
Plan Actual
Shift 3
Shift 4
Implement Step 3 ( Tentative Standard )
Shift 1
Shift 2
Implement Step 2 ( Countermeasure of SOC & HAT )
Shift 1
Shift 2
Shift 3
Shift 4
Shift 3
Shift 2
Autonomous Maintenance Master Plan - First Phase
2015
Shift 1
S.No Activity
2013 2014
Implement Step 0 & Step 1 ( Initial Cleaning )
AM Master plan and Activity Glimpses
21. AM Step 2 Training & Activity Status :
39 40 39 40
158
43 43 43 43
172
0
20
40
60
80
100
120
140
160
1 2 3 4 Total
Shift
Total Members & Trained / Shift
Total Trained
Total Members
Step 2 Training
completed for
92% AM Teams
22. AM Step 2:Source of Contamination and Hard to Access Activities:
Total # of 315 Source of
contamination and 125
Hard to Accesses
Identified by AM in All
equipment's
23. AM Step 2: One Point Lesson Activities:
Number of 201
OPL reported by
the teams
24. AM Step 2: Kaizen Implementation Status
Kaizen is our approach to
Continuous Improvement !!!
104 Kaizen Idea 63
implemented and 41 in
progress
26. Zone (Where) Illustration Work Type Sr. No. Critical Parts (Which)
Qty of
Ctrictical
Parts.
C L R I Standards (What should be) Method
Tools and
handling
Time
(min)
Cycle Who
During
operation
During
stoppage
Impact (Breakdown,
Accident, Cost)
Electrical 1 Motor encoder 2 x x x Clean and tight visual & physical N I 40 M Engg b Breakdown
Electrical x x x Clean and Not damage. visual & physical N I 20 M Engg b
B/A/C
OPS x Clean and Not damage. visual N 5 D OPS b
B/A/C
Electrical x x Working Well visual I 20 M Engg b
A/C
OPS x Working Well visual N 5 D OPS Forman b
A/C
Electrical 4 Motor Terminal conection 2 x x x Tight and Not Damage. visual & physical N I 40 3M Engg b
B
Electrical 5 Motor insulation value check 2 x x Check with Megger 50 to 100 mmegaohms visual I 80 M Engg b
B
Electrical 6 Motor lubrication 2 x x x x Change old grease with new one. visual & physical N I 30 M Engg b
B
Mechanical 7
Gear box oil level
2 x x Clean and in max level visual
I 2 M Engg b
B
Mechanical 8
Gear box mounting bolt
x x Tight and not loose visual
I 5 M Engg b
B
Mechanical 9
Drive chain
2 x x x Lubricated tight and no damage. visual & physical N I 10 M Engg b
B
Mechanical 10
Motor mounting
2 x x bolt are tight visual I 4 M Engg b
B
Mechanical x x x Not damaged. visual & physical N I 2 M Engg b
B
OPS x Not damaged. 2 M Engg b
B
Mechanical 12
Motor coupling bolt
16 x x Tight visual I 6 M Engg b
B
Mechanical 13
Drive wheel &sprocket
2 x Not damaged. visual I 2 M Engg b
B
Electrical x x Not worn out, air pressure, bolts tight visual I 40 M Engg b
B/A/C
OPS x Not worn out visual N 5 D OPS b b
B/A/C
Mechanical 15
Brake adjustment
2 x x Per indicated adjustment visual
I 10 M Engg b
A/C
Mechanical 16
Trurstor brake mounting
2 x x Tight visual
I 4 M Engg b
A/C
Electrical x x x Clean and not damaged. visual & physical N I 40 M Engg b
B
OPS x Clean and not damaged. visual N 10 D OPS Forman b
B
Electrical x x x Clean and not damaged. visual & physical N I 10 M Engg b
B
OPS x Clean and not damaged. visual N 10 D OPS Forman b
B
Electrical 19
hydrulic tank oil level guage
2
x
x x Clean and visible and no damged visual & physical N I 10 M Engg b
B
Electrical 20
Hydraulic Power Pack solenoid coils
12 x x Clean and tightness connections. visual
I 30 M Engg b
B
Electrical 21
Hydraulic Power Pack temperature guage
2 x x Clean and visible and no damged visual I 10 M Engg b
B
Electrical 22
Motor terminal conection
2
x
x Clean and tightness connections. visual
I 30 3M Engg b
B
Electrical 23 Motor insulation value check 2 x x Check with Megger 50 to 100 mmegaohms visual
I 40 M Engg b
B
Mechanical 24
Cylinder
4 x x Check for leak visual I 5 M Engg b
B
Mechanical 25
Cylinder pin
8 x x Intact visual
I 5 M Engg b
B
Mechanical 26
Check hydraulic hoses
20 x x Clean and No leak visual I 10 M Engg b
B
Mechanical 27
Power Pack oil level and leaking check
2 x x Clean and No leakages visual
I 10 M Engg b
B
Mechanical 28
Motor coupling check
2 x x x Check for damaged and tightness. visual & physical N I 4 M Engg b
B
Tire guard chain
Wheel Driving
Motors & Gearboxes
Gantry
Eroomside &
Engine Side
Wheel Turning
System
Equipment description : RTG-37 Equipment number : RTG 37
Gantry anticollision limit switch 8
4
24
4Sensors
LImit Switches
Gantry warning device(horn&light)
Tire 8
2
2
14
17
18
11
3
AM Step 3: Equipment standard implementation plan (RTG)
27. AM Step 3: Equipment check sheet implementation plan (TT)
Number of 120 AM
Operators start
implementation in
TT , EH , RS
