TPM by Chandan Jha
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The document provides an overview of Total Productive Maintenance (TPM). It begins with definitions of TPM and its history originating from preventive maintenance practices in the US that were developed into productive maintenance approaches in Japan. The document outlines the objectives and benefits of TPM, as well as lists certified companies. It describes the goals, participants, strategies, and pillars (such as autonomous maintenance, 5S, and planned maintenance) that are core to TPM. Throughout, it provides details on the philosophy and approaches involved in TPM for improving productivity, equipment effectiveness, and eliminating losses and defects.
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TPM by Chandan Jha
- 1. WELCOME TO THE WORLD OF TPM 11 Prepared by : Chandan jha
- 2. TPM 2 Prepared by : Chandan jha
- 3. ContentsContentsDefinition History and origin, List of TPM certified company. Objective Benefits of TPM Why TPM, TPM Goal TPM Participants TPM Strategies Pillars of TPM Op/Maint partnership Autonomous maintenance Slogans Conclusion 3 Prepared by : Chandan jha
- 4. Definition “TPM is a management process developed for improving productivity by making processes more reliable and less wasteful.” 4 Prepared by : Chandan jha
- 5. HISTORY AND ORIGIN FROM TO United States Henry Ford Preventive Maintenance Japan Nippon Denso Productive Maintenance 5 Prepared by : Chandan jha
- 6. HISTORY CONT’D… Preventive maintenance along with Maintenance prevention and Maintainability Improvement gave birth to Productive maintenance. By then Nippon Denso had made quality circles, involving the employees participation. Thus all employees took part in implementing Productive maintenance. 6 Prepared by : Chandan jha
- 7. HISTORY CONT’D… TPM is a innovative Japanese concept which can be traced back to 1951. However the concept of preventive maintenance was taken from USA. Nippondenso was the first company to introduce plant wide preventive maintenance in 1960. Nippondenso which already followed preventive maintenance also added Autonomous maintenance done by production operators. 7 Prepared by : Chandan jha
- 8. HISTORY CONT’D… Whereas in most production settings the operators are not viewed as a member of the maintenance team, in TPM the machine operators are trained to perform many of the day-to-day tasks of simple maintenance and fault-finding. 8 Prepared by : Chandan jha
- 9. List of TPM certified company. Electrosteel Castings Limited Exide Industries Limited Indian Oil Corporation Limited Jamshedpur Utilities and Services Company Limited MRF Limited Munjal Showa Limited National Engineering Industries Limited Brakes India Ltd. Pad 9 Prepared by : Chandan jha
- 10. List of TPM certified CONT’D… Brakes India Ltd. Foundry Div., Sholinghur Galaxy Surfactants Ltd. Taloja and Tarapur Hindustan Unilever Ltd. Khamgaon Shriram Pistons & Rings Ltd. Sundram Fasteners Ltd. Hosur Sundram Fasteners Ltd. Pondicherry Brakes India Ltd. Nanjangud Hindustan Unilever Ltd.Haldia 10 Prepared by : Chandan jha
- 11. OBJECTIVE To restructure the corporate culture through behavioral changes and equipment improvements. 11 Prepared by : Chandan jha
- 12. Similarities and differences between TQM and TPM Total commitment to the program by upper level management is required in both programs Employees must be empowered to initiate corrective action. A long range outlook must be accepted as TPM may take a year or more to implement and is an on-going process Changes in employee mind-set toward their job responsibilities must take place as well. 12 Prepared by : Chandan jha
- 13. WHY TPM? Safe Work Environment Job Security Quality Increased Productivity Improved Skills 13 Prepared by : Chandan jha
- 14. WHY TPM?CONT’D… Avoid wastage in a quickly changing economic environment. Produce goods without reducing product quality. Reduce cost. Produce a batch quantity at the earliest possible time. 14 Prepared by : Chandan jha
- 15. WHY TPM?CONT’D… Creating company culture for maximum efficiency. Striving to prevent losses with minimum cost The essence of team work (small group activity) focused on condition and performance of facilities to achieve zero loss. Goods send to the customers must be non defective. 15 Prepared by : Chandan jha
- 16. GOAL OF TPM Zero Accide nts Zero Product Defect s Zero Equipment Failures 16 Prepared by : Chandan jha
- 17. Team of TPM TPM involves everyone in the organization from operators to senior management In equipment improvement. It encompasses all most all departments. 17 Prepared by : Chandan jha
- 18. CONT’D… The departments including: Maintenance Operations/production Tool Room Design Engineering Project Engineering Construction Engineering Inventory and Stores Purchase Accounting and Finance 18 ,etc Prepared by : Chandan jha
- 19. TPM STRATEGIES Conduct more frequent and thorough inspection and cleaning of machines to discover minor discrepancies before they become failures. Enhance PMs to correct minor defects and prevent failures. 19 Prepared by : Chandan jha
- 20. TPM STRAIT. CONT’D… Modify Operations to reduce need for maintenance. Elevate all employees’ knowledge, skill and role in improving equipment performance. – Engineers, Line Leaders, maintenance technicians, and especially production operators. 20 Prepared by : Chandan jha
- 21. TPM STRAIT. CONT’D… TPM Only clean machines and equipment problems visually apparent!!! Cleaning is Inspection. CLEANING IS CHECKING ! 21 Prepared by : Chandan jha
- 22. TPM STRAIT. CONT’D… The starting point for TPM is implementing routine inspections by production operators. “Autonomous maintenance” –Users/operators perform continuous inspection for minor defects as well as continuous cleaning, adjustment, and tidying up the loosen parts. 22 Prepared by : Chandan jha
- 23. TPM STRAIT. CONT’D… Outline a detailed master deployment plan. Improve the effectiveness of each piece of equipment and concern person. Develop an autonomous maintenance program for operators. 23 Prepared by : Chandan jha
- 24. TPM STRAIT. CONT’D… Conduct training to improve operation and maintenance skills. Develop an early equipment management program. Continuous improvement. Develop a planned for preventive maintenance program. 24 Prepared by : Chandan jha
- 25. PILLER OF TPM Autonomous Maintenance 5-S Jishu Hozen Kaizen Planned Maintenance Quality Maintenance Office TPM Education & Training Safety, Health & Environment Development Management 25 Prepared by : Chandan jha
- 26. Autonomous Maintenance Activities where each operator performs timely inspection, lubrication, consumable parts replacement, repair, troubleshooting, accuracy checks, etc, of their own equipment. T P M OIL 26 Prepared by : Chandan jha
- 27. 5-S You can’t see problems clearly when the workplace is in disarray Cleaning and organizing the workplace helps the team to uncover problems Making problems visible is the first step of improvement Clean machines and workplace create pride & Safety TPM is the only tool to win the race, Keeping 5-S as its base. 27 Prepared by : Chandan jha
- 28. JISHU HOZEN PolicyUninterrupted operation of equipments. Flexible operators to operate and maintain other equipments. Eliminating the defects at source through active employee participation. Stepwise implementation of JH activities. JISHU HOZEN TargetsPrevent the occurrence of 1A/1B because of JH. Reduce oil consumption by 50%. Reduce process time by 50%. Increase use of JH by 50%. 28 Prepared by : Chandan jha
- 29. JISHU HOZEN CONT’D… Steps in JISHU HOZENPreparation of employees. Initial cleanup of machines. Take counter measures. Fix tentative JH standards. General inspection. Autonomous inspection. Standardization. Autonomous management. 29 Prepared by : Chandan jha
- 30. KAIZEN Kai means change and Zen means good The principle behind is a very large number of small improvements are move effective in an organizational environment than a few improvements of large value. Policy - Practice concepts of zero losses in every activity - To achieve cost reduction targets in all resources - To improve over all plant equipment effectiveness - Focus of easy handling of operators Target - Achieve and sustain zero loses with respect to minor stops, measurement and adjustments - It also aims to achieve 30% manufacturing cost reduction 30 Prepared by : Chandan jha
- 31. PLANNED MAINTENANACE It is aimed to have trouble free machines and equipments producing defect free products for total customer satisfaction. Break down into 4 categories. Preventive Maintenance Breakdown Maintenance Corrective Maintenance Maintenance Prevention Target Zero equipment failure and break down. Improve reliability and maintainability by 50%. 31 Prepared by : Chandan jha
- 32. PM-CONT’D… PMReduce maintenance cost by 20% - Ensure availability of spares all the time Six steps in planned maintenance 1. Equipment evaluation and recoding present status 2. Restore deterioration and improve weakness 3. Building up information management system 4. Prepare time based information system 5. Prepare predictive maintenance 6. Evaluation of planned maintenance 32 Prepared by : Chandan jha
- 33. QUALITY MAINTENANCE It is aimed towards customer delight through highest quality through defect free manufacturing. QM activity is to set equipment conditions that preclude quality defects, based on the basic concept of maintaining perfect equipment to maintain perfect quality of products. Policy o Defect free conditions and control of equipments o QM activities to support quality assurance o Focus of prevention of defects at source o Focus on poka-yoka (full proof system) 33 Prepared by : Chandan jha
- 34. QM-CONT’D… QMIn-line detection and segregation of defects - Effective implementation of operator quality assurance Target - Achieve and sustain customer complaints at zero - Reduce in-process defects by 50% - Reduce cost of quality by 50% Quality defects are classified as customer end defects and in house defects. 34 Prepared by : Chandan jha
- 35. QM-CONT’D… QMTarget - Achieve and sustain downtime due to want men at zero on critical machines. - Achieve and sustain zero losses due to lack of knowledge/skills/techniques. - Aim at 100% participation in suggestion scheme. Steps in education and training activities - Setting policies and priorities and checking present status of education and training - Establish a training system for skill upgrading - Preparation of training calendar - Evaluation of activities and study of future approach 35 Prepared by : Chandan jha
- 36. OFFICE TPM Office TPM should be started after activating four other pillars of TPM (JH,KK,QM,PM). Office TPM addresses 12 major losses - Processing loss - Cost loss in areas like accounts, marketing and sales - Communication loss - Idle loss - Set-up loss - Accuracy loss - Office equipment breakdown, telephones and fax - Communication channel breakdown - Time spent on retrieval of information - Non availability of correct on line stock status 36 Prepared by : Chandan jha
- 37. OFFICE TPM CONT’D… Customer complaints due to logistics - Expenses on emergency dispatches/purchases Benefits - Involvement of all people in support functions for focusing on better plant performance. - Better utilized work area - Reduce repetitive work - Reduce administrative costs - Reduction in number of files - Reduction in office equipment - Reduce customer complaints - Reduce manpower - Clean and pleasant work environment 37 Prepared by : Chandan jha
- 38. Education & Training It is aimed to have multi skilled employees whose morale is high and who has eager to come to work and perform all required functions effectively and independently. They are trained to achieve 4 phases of skills Phase 1 : Do not know Phase 2 : Know the theory but cannot do Phase 3 : Can do but cannot teach Phase 4 : Can do and also teach Policy - Focus on improvement of knowledge and skills - Create a training environment for self learning - Training to remove employee fatigue and make work enjoyable 38 Prepared by : Chandan jha
- 39. SAFETY,HEALTH AND ENVIRONMENT Target - Zero accident - Zero Health damage - Zero fires It helps to create a safe workplace and a surrounding area that is not damaged by our process or procedures. It plays an active role in each of the other pillars on a regular basis. To create awareness among employees various competitions like safety slogans ,posters etc can be organized at regular intervals. 39 Prepared by : Chandan jha
- 40. OMP - OPERATOR MAINTENANCE PARTNERSHIP Operator training in TPM Operator basic equip inspection & tooling checks Operator basic cleaning Operator lubrication check One point lessons (capture knowledge) TPM 40 Prepared by : Chandan jha
- 41. CONT’D… The Ethics of operator is to operate the equipment with high skills level, in order to reduce the down time. The Ethics of Maintenanc e team is to upgrade the equipment to perform it better. 41 Prepared by : Chandan jha
- 42. CONT’D… Operator and Equipment Mother and baby 42 Prepared by : Chandan jha
- 43. SEE THE BELOW IMAGES….. 43 Prepared by : Chandan jha
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- 46. 46 Prepared by : Chandan jha
- 47. 47 Prepared by : Chandan jha
- 48. WHAT WAS COMMON IN ABOVE IMAGES ? 48 Prepared by : Chandan jha
- 49. LACK OF KNOWLEDGE ? 49 Prepared by : Chandan jha
- 50. LACK OF AWARENESS ? 50 Prepared by : Chandan jha
- 51. LACK OF TRAINING? 51 Prepared by : Chandan jha
- 52. THE ANSWER IS : “LACK OF OWNERSHIP” THAT IS ATTITUDE PROBLEM. 52 Prepared by : Chandan jha
- 53. ATTITUDE / THOUGHT 53 Prepared by : Chandan jha
- 54. THOUGHT CHANGE Old concept New concept I operate the machine and some body maintains it. I operate the machine and I maintain it. 54 Prepared by : Chandan jha
- 55. SEE THE BELOW IMAGES….. 55 Prepared by : Chandan jha
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- 60. What was common in above pictures 60 Prepared by : Chandan jha
- 61. THE ANSWER IS… 61 Prepared by : Chandan jha
- 62. WHAT IS THE GOAL OF OPERATOR AUTONOMOUS MAINTENANCE? “Keeping one's own equipment in good condition by oneself ”. 62 Prepared by : Chandan jha
- 63. SLOGANS TPM In, Losses Out. Machine not tight, job not right. Organization without TPM; Building without foundation. Farmer is the backbone of a country; TPM is the backbone of industry. Accept TPM with a Positive Attitude Achieve Success of high Magnitude. 63 Prepared by : Chandan jha
- 64. SLOGANS TPM is the foundation of factory. Invest minutes for TPM; Gain hours for production. Your future is bright, when the TPM you practice is right. Don’t be a fool, use TPM tool. 64 Prepared by : Chandan jha
- 65. AT LAST “TPM is a Lean tool for Quality and Productivity” 65 Prepared by : Chandan jha
- 66. CONSLUSION Today, with competition in industry is high. TPM may be the only tools that stands us success. 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" . If everyone involved in a TPM program, an unusually high rate of return compared to resources invested may be expected. 66 Prepared by : Chandan jha
- 67. I sincerely thank you for your co-operation and consideration for the growth of TPM. THANK YOU, Presented by: CHANDAN JHA 67 [email protected]