Presented By – Ankur Kumar
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What is maintenance ?
Introduction to Total Productive Maintenance (TPM).
Why TPM need ?
TPM History
TPM Objectives
TPM targets
Similarity and difference between TPM and TQM
8 Pillars of TPM.
Why is TPM so popular and important ?
Company checklist
Effectiveness of TPM.
Benefits of TPM
Losses of TPM 2
What is
Maintenance?
Activity involved in maintaining something in good
working order.
The process of preserving a condition or situation or the
state of being preserved.
Example : You must make sure to do regular maintenance
on all of your machinery to keep them running up to code.
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Introduction to TPM
T: TOTAL
Participation of all Employees.
Includes all Departments, operation, equipment and process.
P: PRODUCTIVE
Pursue the maximization of efficiency of the production
system by making all loses zero.
Zero accidents, Zero defects, Zero breakdowns.
M: MAINTENANCE
To improve the efficiency of the equipment.
Maintenance means the entire life cycle of the production
system.
TOTAL PRODUCTIVE MAINTENANCE
Definition
Total Productive Maintenance (TPM) is the
systematic execution of maintenance by all
employees through small group activities.
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Avoid wastage
Producing goods without reducing
product quality.
Reduce cost.
Goods send to the customers must
be non defective.
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TPM first introduced in Japan 20 years ago and rigorously been applied in
past 10 years
• TPM planning & implementation in Japanese factories supported by JIPM
(Japan Institute of Plant Maintenance)
• Awarded yearly prizes to various industries:
Automotive, Metals, Chemicals, Rubber, Food, Glass etc.
Initially implemented in
high-to-medium volume production areas
Later successfully applied in:
Low-volume production
High-to-low volume assembly
Development areas
Whole range of industry 7
1. Increase production while, at the same time, increasing
employee morale and job satisfaction.
2. Hold emergency & unscheduled maintenance to a minimum.
3. To provide the safe and good working environment to the
worker.
4. Achieve Zero Defects, Zero Breakdown and Zero accidents in
all functional areas of the organization.
5. Involve people in all levels of organization.
6. Form different teams to reduce defects and Self Maintenance.
7. To fulfill Regulatory compliances.
To provide the safe and good working environment
to the worker.
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1. PRODUCTION
I). Obtain Minimum 80% Overall Production Efficiency
ii). Obtain Minimum 90% Overall Equipment Effectiveness
iii). Run the Machine during lunchtime
2. QUALITY
Operate in a manner, so that there are no customer complaint
3. COST
Reduce the manufacturing cost as much as possible
4. DELIVERY
Achieve 100% success in delivering the goods as required by the
customer
5. SAFETY
Maintain an accident free environment
6. MULTI TASK
Develop multiskilled & flexible workers.
Total commitment of upper level management.
Employees must be empowered to initiate corrective action.
Category TQM TPM
Quality ( Output and Equipment ( Input and
Object
effects ) cause )
Systematize the Employees
Mains of
management. It is participation and it is
attaining goal
software oriented hardware oriented
Elimination of losses
Target Quality for PPM
and wastes.
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5S
JH
PM
QM
E&T
DM
SHE
OTPM
PILLAR 1 – Individual Improvement
• Improvement on every one’s activity.
• Improvement is to eliminate Production losses and cost reduction.
• Improvement in Reliability, Maintainability, and cost.
PILLAR 2 - Autonomous Maintenance
A collaborative team activity involving production, maintenance, and engineering
Maintaining Basic conditions on shop floor & in Machines.
All over participation through TPM Circles.
An approach that
Develops operating and maintenance skills
Strengthens communication and cooperation
PILLAR 3 - Planned Maintenance
• Logical analysis “Real causes for real counter measures”.
• Focus on Prevention.
• It is aimed to have trouble free machines and equipments producing defect
free products for total customer satisfaction.
Example: Preventive Maintenance, Breakdown Maintenance, etc.,
PILLAR 4 - Quality Maintenance
• Developing perfect machine for perfect Quality.
• Eliminating In – Process defects and custom complaints.
PILLAR 5 - Education & Training
• Skills development for uniformity of work practices on machines.
• Skills for Zero defects, Zero breakdowns & Zero accidents.
• Multi Skilled employees in all departments
• Steps in Educating and training activities :
• Setting policies and priorities and checking present status of education and training.
• Establish of training system for operation and maintenance skill up gradation.
• Training the employees for upgrading the operation and maintenance skills.
• Preparation of training calendar.
• Evaluation of activities and study of future approach.
PILLAR 6 - Development Management
Developing machines for “high equipment effectiveness”.
Quick process for developing new products.
PILLAR 7 - Safety, Health & Environment
• Zero accidents and Zero hazards at works.
• Zero Pollution at Plant and Environment
PILLAR 8 - Office TPM
Office TPM should be started after activating from other pillars of TPM.
Office TPM must be flowed to improve productivity, efficiency in the administrative
function and identify eliminate losses.
This includes analyzing process and procedure towards increased office automation.
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It guarantees dramatic results (Significant tangible results)
Reduce equipment breakdowns
Minimize idle time and minor stops
Less quality defects and claims
Increase productivity
Reduce manpower and cost
Lower inventory
Reduce accidents.
Visibly transform the workplace (plant environment)
Through TPM, a filthy, rusty plant covered in oil and grease, leaking fluids and
spilt powders can be reborn as a pleasant and safe working environment
Customers and other visitors are impressed by the change
Confidence on plant’s product increases
Raises the level of workers knowledge and skills
As TPM activities begin to yield above concrete results, it helps:
The workers to become motivated
Involvement increases
Improvement suggestions proliferate
People begin to think of TPM as part of the job 17
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Effectiveness of TPM
•Productivity enhancement
RESULTS •Cost Reduction
EXPECTED •Delivery period shortening
•Sales Expansion
•Employee Involvement
ESSENTIAL •Top management Commitment
REQUIREMENTS •Management Tools
BENEFITS OF TOTAL PRODUCTIVE MAINTENANCE
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