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PQT - Total Productive
Maintenance
TPM overview
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T P MTotal Productive
Maintenance
What’s TPMHow TPM
works
Concept Zero
TPM TargetsWhy TPM
Objectives of TPM
What’s T P M• TPM was developed in the 1970's
as a method of involving machine operators in the preventive maintenance of their machines – a reaction to increasing specialization and
centralization of the maintenance function that had created division-of-labor barriers between operators and the maintenance of their machines and equipment.
– Also creating a sense of ownership in workers with Autonomous Maintenance
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Objectives of T P M• The overriding objective of TPM is the
elimination of LOSSES. Losses, or waste, includes equipment downtime, defects, scrap, accidents, wasted energy, and labor inefficiency.
• TPM was introduced to achieve some of the following important objectives:– Safer working environment, Job security– Producing goods with improved quality and machine
reliability– Improved financial performance– Produce a low batch quantity at the earliest possible
time.– Goods send to the customers must be non defective
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Why T P M
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Before 1 Severe problem occured, there were 300 minor and 29 major problems to handle.
Source: Kaizen Institute, Frankfurt
Heinrich‘s Law
TPM is a tool which addresses potential signs of machine break-downs and is therefore an important instrument to prevent total machine crashes.
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29
300
Severe problem
Minor problems
Major problems
Concept ZERO• The goal of TPM is to drive all waste to
zero: Zero Accidents, Zero Defects, Zero Breakdowns.
• The Concept of Zero is built upon Poka-Yoke, in the design of the process to make it impossible to make and pass on defects.
• Poka-Yoke concepts are also commonly applied to equipment to prevent breakdowns.
• Poka (Mistakes), Yokeru (Avoid) or Mistake Proofing (Japanese Term)
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Performance Measure and 6 Losses• Overall Equipment Effectiveness (OEE) is the
performance measure of TPM.• Thus factors affecting OEE / TPM:
• Availability• Performance• Quality
– Associated 6 big losses are:• Availability Losses: Breakdown losses caused by
the equipment; Set-up and adjustment losses• Performance Losses: Minor stoppage losses;
Speed losses• Quality Losses: Quality defect and rework
losses; Yield losses
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Pillars of TPM
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How it Works
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Types of Maintenance • Breakdown Maintenance: This occurs when equipment
fails but does not affect production or operation or extra costs other than repairs
• Preventive Maintenance: A daily maintenance designed to maintain equipment against failing and also improved health condition– Periodic Maintenance: A time based maintenance– Predictive Maintenance: Maintenance based on
condition monitoring by employing surveillance system
• Corrective Maintenance: Redesigning equipment with weakness to improve reliability
• Maintenance Prevention: This indicates design of new machine by Cross functional teams after thorough study on weakness of current machines
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TPM Targets
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P roduction:Obtain Minimum 80% OPE (Overall Process Effectiveness)Obtain Minimum 90% OEE (Overall Equipment Effectiveness)Run the machines even during lunch. (Lunch is for operators and not for machines!)
Q uality:Operate in a manner, so that there are no customer complaints.
C osts:Reduce the manufacturing cost by 30%.D elivery:Achieve 100% success in delivering the goods as required by the customer.
S afety:Maintain a accident free environment.
M aintenance:Develop Multi-skilled and flexible workers. And Cross functional teams