Module-4 Total Productive Maintenance TPM) (2).pptx

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1. Module-4 : Total Productive Maintenance (TPM) 21MT61:   Condition Monitoring & Management

2. Introduction Total Productive Maintenance (TPM) is a people-centered methodology designed to optimize equipment effectiveness and eliminate breakdowns. Significance of TPM in Manufacturing Cost Impact Equipment Effectiveness Operator Involvement CLAIR Activities:  CLAIR stands for Clean, Lubricate, Adjust, Inspect, Minor Repair. Impact on Maintenance Staff: Focus Shift, Strategic Benefits

3. 5S Methodology Sort Systemize Shine Standardize Sustain

4. Objectives of TPM Avoid wastage in a rapidly changing economic environment. Produce goods without compromising quality. Reduce costs and produce low batch quantities quickly. Ensure products sent to customers are defect-free.

5. Team-Based Activities in TPM Collaboration Maintainability Improvement Maintenance Prevention Benefits of TPM Improved equipment availability and reduced maintenance costs. Enhanced maintenance efficiency and reduced repair time. Increased production worker involvement in maintenance, raising their skills and effectiveness.

6. Pareto Analysis   As a first step in reliability data analysis we can use the Pareto principle of the ‘significant few and the insignificant many’. Pareto Analysis, based on the Pareto principle or the ' 80/20 rule ,' suggests that a large proportion of failures in a product are due to a small number of causes. Importance of Pareto Analysis Focus on Significant Issues Economical Use of Resources

7. Steps in Pareto Analysis Collect Failure Data Categorize Failures Create a Pareto Plot Example: Domestic Washing Machine Failure Data Analysis of Failure Data Program Switch- timer motor armature open-circuit, timer motor end bearing stiff, miscellaneous failures.

8. Outlet Pump-  leaking shaft seal allowing water to reach motor coils, other failures. High-Level Switch-  failure of spot weld, other failures. Corrective Actions Based on Analysis: Program Switch- improving the timer motor manufacturing process. Outlet Pump-  Consider reorienting the pump, Improve the seal to reduce leaks. High-Level Switch-  Improve the quality of spot welds

9. Further Considerations :  Starting Capacitor Failures. Importance of Good Data for Decision-Making. Applications of Pareto Analysis Down-Time Contribution Repair Cost

10. ABC Analysis A – Class inventory are most valuable and requires more attention B – Class inventory are intermediate and requires moderate care C – Class inventory are least valuable and so does not need much attention. A-B-C analysis takes care of two aspects : (a) the annual consumption, and (b) the cost.  Consider an example of motor bike spare parts management in a Service centre . 

11. 'C' class These types of issues are classified under the 'C' class, indicating they are low-cost but frequent maintenance concerns. (gear wire, a brake wire, or accelerator wire, tyre failure problems, colour coating, replacement of head lamp or indicator lamps, seat covers, spark plug etc.)

12. ‘B’ class items Spare parts such as gears, seat, rim etc.,

13. ‘A’ class items The engine, piston-cylinder etc are rarely changed. So such spares can be considered as ‘A’ class items.

14. Thank You