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What is maintenance and their types
What isTPM
Why TPM need
TPM History
TPM Objectives
TPM targets
Similarity and difference between TPM andTQM
Pillars ofTPM
Why is TPM so popular and important
Company checklist
Benefits ofTPM
Losses ofTPM
Conclusion
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What is Maintenance?
The Management,control,execution and
quality assurance of activities which
ensure the achievement of optimum
availability and performance of a plant
in order to meet business objectives.
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Types Of Maintenance :
Preventive Maintenance
Predictive Maintenance
Scheduled Maintenance
Breakdown Maintenance
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T: TOTAL
❖ Participation of all Employees.
❖ Include 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.
It is a Japanese approach for
Creating company culture for maximum efficiency
Striving to prevent losses with minimumcost
Zero breakdowns and failures, Zero accident, and
Zero defects etc.
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
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TPM first introduced in Japan in1950 and rigorously
been applied by Nippon Denso in1961 and from 1971 by
various companies in Japan.
Seiichi Nakajima was the founder of TPM System
• 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.
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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
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Avoid wastage in a quickly changing economic
environment.
Producing goods without reducing product
quality.
Reduce cost.
Goods send to the customers must be non
defective.
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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.
“If you focus on result you will
never change.
If you focus on change you
will get Result.”
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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. MULTITASK
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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PILLAR 1 - 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 2 - Focused Improvement
Improvement on every one’s activity.
Improvement is to eliminate Production losses and cost
reduction.
Improvement in Reliability, Maintainability, and cost.
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.,
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PILLAR 4 - Quality Maintenance
• Developing perfect machine for perfect Quality.
• Eliminating In – Process defects and custom
complaints.
Policy :
• Defect free conditions and control of equipments.
• QM activities to support quality assurance.
• Focus of prevention of defects at source
• Effective implementation of operator quality assurance
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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.
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PILLAR 6 - Development Management
• Developing machines for “high equipment
effectiveness”.
• Quick process for developing new
products. Example: KAIZEN
Kaizen Policy :
• Relentless pursuit to achieve cost reduction targets in all
resources.
• Relentless pursuit to improve over all plant equipment
effectiveness.
• Extensive use of PM analysis as a tool for eliminating
losses.
• Focus of easy handling of operator
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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. Office TPM covers twelve major
losses. These are:
1. Processing loss
2. Cost loss including in areas such as procurement, accounts marketing
leading to high inventories.
3. Communication loss.
4. Idle loss.
5. Set-up loss.
6. Accuracy loss
7. Office equipment breakdown.
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8. Communication channel breakdown.
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Three main reasons:
1. 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
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2. 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
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3. 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
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Direct Benefits of TPM Indirect Benefits of TPM
1. Increase Productivity 1. Higher confidence level
and Overall Plant among the workers
Efficiency by 1.5 to 2 2. Keep the work place
times clean, neat and
2. Rectify customers attractive
complaints 3. Favorable change in the
3. Reduce manufacturing attitude of the operators
cost by ….percent 4. Achieve goals by working
4. Satisfy the customers as Team
needs by 100% 5. Share knowledge and
5. Reduce accidents experience
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• Breakdown losses
• Setup and adjustment losses
• Idling and minor stoppage losses
• Speed losses
• Quality defects and rework losses
• Start-up/yield losses
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TPM is a Lean tool for Quality and Productivity
Today, with competition in industry at an all time high, TPM may be the only
thing that stands between success and total failure for some companies. It has
been proven to be a program that works. Employees must be educated and
convinced that TPM is not just another "program of the month" and that
management is totally committed to the program and the extended time frame
necessary for full implementation. If everyone involved in a TPM program does
his or her part, an unusually high rate of return compared to resources invested
may be expected.
• TPM may be the only thing that stands between success and total failure for
some companies
• It can be adapted to work not only in industrial plants, but in
construction, building maintenance, transportation, and in a variety of
other situations.
• Easy to operation, Improvement the availability and productivity, make
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operation and area safer.
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