Total Productive Maintenance (TPM).pdf

Information about total productive maintenance. It is related to industry.

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2. What is maintenance and theirtypes
What isTPM
Why TPMneed
TPMHistory
TPMObjectives
TPMtargets
Similarity and difference between TPM andTQM
Pillars ofTPM
Why is TPM so popular andimportant
Companychecklist
Benefits ofTPM
Losses ofTPM
Conclusion
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3. What isMaintenance?
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The Management,control,execution and
quality assuranceofactivitieswhich
ensuretheachievementofoptimum
availability and performance of a plant
in order to meet business objectives.

4. Types Of Maintenance:
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PreventiveMaintenance
PredictiveMaintenance
ScheduledMaintenance
BreakdownMaintenance

5. T:TOTAL
❖Participation ofallEmployees.
❖IncludeallDepartments,operation,equipmentand
process.
P:PRODUCTIVE
❖Pursuethemaximizationofefficiencyoftheproduction
system
by making all loseszero.
❖Zero accidents Zero defects Zerobreakdowns.
M:MAINTENANCE
❖To improve the efficiency of theequipment.
❖Maintenance means the entire life cycle of the production system.

6. It is a Japanese approachfor
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Creating company culture for maximum efficiency
Striving to prevent losses with minimumcost
Zero breakdowns and failures, Zero accident,and
Zero defectsetc.
The essence of team work (small group activity) focused
on condition and performance of facilities to achieve zero loss for
improvement
Involvement of all people from top management to
operator

7. TPM first introduced in Japan in1950andrigorously
been applied byNippon Denso in1961 and from 1971 by
various companies in Japan.
SeiichiNakajimawasthefounderofTPMSystem
•TPM planning & implementation in Japanese factories
supported by JIPM (Japan Institute of PlantMaintenance)
•Awarded yearly prizes to variousindustries:
✓Automotive
✓Metals
✓Chemicals
✓Rubber
✓Food
✓Glassetc.
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8. Initially implementedin
high-to-medium volume productionareas
Later successfully appliedin:
✓Low-volumeproduction
✓High-to-low volumeassembly
✓Development areas
✓Whole range ofindustry
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9. Avoid wastage in a quickly changing economic
environment.
Producing goods without reducingproduct
quality.
Reducecost.
Goods send to the customers must benon
defective.
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10. 1.Increase production while, at the same time, increasing employee
morale and jobsatisfaction.
2.Hold emergency & unscheduled maintenance toa minimum.
3.To provide the safe and good working environment to the worker.
4.Achieve Zero Defects, Zero Breakdown and Zeroaccidents
in all functional areas of theorganization.
5.Involve people in all levels oforganization.
6.Form different teams to reduce defects and Self
Maintenance.
7.To fulfill Regulatory compliances.

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To provide the safe and goodworking
environment to theworker.
“If you focus on result you will
neverchange.
If you focus on change you
will getResult.”

12. 1.PRODUCTION
I). Obtain Minimum 80% Overall ProductionEfficiency
2.
3.
4.
ii)Obtain Minimum 90% Overall EquipmentEffectiveness
iii)Run the Machine duringlunchtime
QUALITY
Operate in a manner, so that there are no customercomplaint
COST
Reduce the manufacturing cost as much aspossible
DELIVERY
Achieve 100% success in delivering the goods as required bythe
customer
5.
6.
SAFETY
Maintain an accident freeenvironment
MULTITASK
Develop multiskilled & flexibleworkers.

13. Total commitment of upper level management.
Employees must be empowered to initiate corrective action.
Category
Object
TQM
Quality ( Outputand
effects)
Mainsof
attaininggoal
Systematize the
management. Itis
softwareoriented
Target Quality forPPM
TPM
Equipment ( Inputand
cause)
Employees
participation and itis
hardwareoriented
Elimination oflosses
andwastes.

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15. PILLAR1-AutonomousMaintenance
A collaborative team activity involvingproduction,
maintenance, andengineering
Maintaining Basic conditions on shop floor & inMachines.
All over participation through TPMCircles.
An approachthat
Develops operating and maintenanceskills
Strengthens communication andcooperation
PILLAR 2 -Focused Improvement
Improvement on every one’sactivity.
Improvement is to eliminate Production losses and cost
reduction.
Improvement in Reliability, Maintainability, andcost.

16. PILLAR3 -PlannedMaintenance
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•Logicalanalysis“Realcausesforrealcountermeasures”.
•FocusonPrevention.
•Itisaimedtohavetroublefreemachinesandequipments
producingdefectfreeproductsfortotalcustomersatisfaction.
Example:PreventiveMaintenance,Breakdown
Maintenance,etc.,

17. PILLAR 4-QualityMaintenance
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•Developing perfect machine for perfectQuality.
•Eliminating In –Process defects andcustom
complaints.
Policy:
•Defect free conditions and control ofequipments.
•QM activities to support qualityassurance.
•Focus of prevention of defects atsource
•Effective implementation of operator qualityassurance

18. PILLAR 5 -Education &Training
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•Skills development for uniformity of work practices onmachines.
•Skills for Zero defects, Zero breakdowns & Zeroaccidents.
•Multi Skilled employees in alldepartments
Steps in Educating and training activities:
•Setting policies and priorities and checking present statusof
education andtraining.
•Establish of training system for operation and maintenance skill
upgradation.
•Training the employees for upgrading the operation and
maintenance skills.
•Preparation of trainingcalendar.
•Evaluation of activities and study of futureapproach.

19. PILLAR 6 -DevelopmentManagement
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•Developing machines for “highequipment
effectiveness”.
•Quick process for developing new
products. Example:KAIZEN
Kaizen Policy:
•Relentless pursuit to achieve cost reduction targets inall
resources.
•Relentless pursuit to improve over all plantequipment
effectiveness.
•Extensive use of PM analysis as a tool foreliminating
losses.
•Focus of easy handling ofoperator

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PILLAR 7 -Safety, Health &Environment
•Zero accidents and Zero hazards atworks.
•Zero Pollution at Plant andEnvironment
PILLAR 8 -OfficeTPM
OfficeTPMshouldbestartedafteractivatingfromotherpillarsof
TPM.OfficeTPMmustbeflowedtoimproveproductivity,
efficiencyintheadministrativefunctionandidentifyeliminate
losses.Thisincludesanalyzingprocessandproceduretowards
increasedofficeautomation.OfficeTPMcoverstwelvemajor
losses.Theseare:
1.Processingloss
2.Cost loss including in areas such as procurement, accountsmarketing
leading to highinventories.
3.Communicationloss.
4.Idleloss.
5.Set-uploss.
6.Accuracyloss
7.Office equipmentbreakdown.
8.Communication channelbreakdown.

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22. Three mainreasons:
1.It guarantees dramatic results (Significant
tangibleresults)
Reduce equipmentbreakdowns
Minimize idle time and minorstops
Less quality defects andclaims
Increaseproductivity
Reduce manpower andcost
Lowerinventory
Reduceaccidents
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23. 2.Visibly transform theworkplace
(plantenvironment)
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Through TPM, a filthy, rusty plant covered in oil and
grease,leakingfluidsandspiltpowderscan be reborn as a
pleasant and safe working environment
Customers and other visitors are impressed bythe
change
Confidenceonplant’sproductincreases

24. 3.Raises the level of workers knowledge and skills
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As TPM activities begin to yield above
concrete results, ithelps:
The workers to becomemotivated
Involvementincreases
Improvement suggestionsproliferate
People begin to think of TPM as part of thejob

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28. Indirect Benefits ofTPM
1.Higher confidence level
among theworkers
2.Keep the workplace
clean, neat and
attractive
3.Favorable change inthe
attitude of theoperators
4.Achieve goals byworking
asTeam
5.Share knowledgeand
experience
Direct Benefits ofTPM
1.IncreaseProductivity
and Overall Plant
Efficiency by 1.5 to 2
times
2.Rectifycustomers
complaints
3.Reducemanufacturing
cost by….percent
4.Satisfy thecustomers
needs by100%
5.Reduceaccidents

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30. •Breakdownlosses
•Setup and adjustmentlosses
•Idling and minor stoppagelosses
•Speedlosses
•Quality defects and reworklosses
•Start-up/yieldlosses
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31. TPM is a Lean tool for Quality andProductivity
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Today,withcompetitioninindustryatanalltimehigh,TPMmaybetheonly
thingthatstandsbetweensuccessandtotalfailureforsomecompanies.Ithas
beenproventobeaprogramthatworks.Employeesmustbeeducatedand
convincedthatTPMisnotjustanother"programofthemonth"andthat
managementistotallycommittedtotheprogramandtheextendedtimeframe
necessaryforfullimplementation.IfeveryoneinvolvedinaTPMprogramdoes
hisorherpart,anunusuallyhighrateofreturncomparedtoresourcesinvested
maybeexpected.
•TPM may be the only thing that stands between success and total failurefor
somecompanies
•It can be adapted to work not only in industrial plants, but in
construction, building maintenance, transportation, and in a variety of
othersituations.
•Easy to operation, Improvement the availability and productivity, make
operation and areasafer.

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