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IMPLEMENTATION OF TPMB.RAJESH15MM07TOTAL PRODUCTIVE MAINTENANCET: 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. Maintenance is not only to repair and maintain the machines.

WHY WE NEED TPM ?

The major objectives of the TPM are :Avoid wastage in quickly changing environment.Reduce Cost of Manufacturing.Produce a low batch quantity at the earliest possible time.Goods send to Customers must be non defective

TPM OBJECTVESIncrease production while, at the same time, increasing employee morale and job satisfaction.Hold emergency & unscheduled maintenance to a minimum. To provide the safe and good working environment to the worker. Achieve Zero Defects, Zero Breakdown and Zero accidents in all functional areas of the organization.Involve people in all levels of organization.Form different teams to reduce defects and Self Maintenance.

BENEFITS OF TPMIncreased Employee MoraleIncreased ProductivityImproved Sharing and Working as a TeamImproved tidines and cleaning of the working placeImproved Product QualityImproved Customer SatisfactionReduced CostsImproved Delivery TimeEnhanced safety RecordsImproved ImageImproved Reputation

TYPES OF MAINTENANCEBreakdown MaintenancePreventive MaintenanceePeriodic MaintenancePredictive MaintenanceCorrective MaintenanceMaintenance Prevention

TPM TARGETSPRODUCTIONI). Obtain Minimum 80% Overall Production Efficiencyii). Obtain Minimum 90% Overall Equipment Effectivenessiii). Run the Machine during lunchtimeQUALITY Operate in a manner, so that there are no customer complaintCOST Reduce the manufacturing cost as much as possibleDELIVERY Achieve 100% success in delivering the goods as required by the customerSAFETY Maintain an accident free environmentMULTYTASK Develop multiskilled & flexible workers.

PILLARS OF TPM

ROLES OF PRODUCTION AND MAINTENANCE IN TPM

MEASUREMENT OF TPM EFFECTIVENESS Breakdown losses Set-up and adjustment losses Minor/idling stoppage losses Reduced speed losses Defect/rework losses Start-up losses

CASE STUDY OF TPM IMPLEMENTATION Background information of the electronics manufacturing company introduction-preparatory stage of TPM implementation step 1. Establishment of TPM organization Step 2. Organization of TPM officeStep 3. Introductory education and campaignStep 4. Setting the policies for TPMStep 5. Creation of master plan for TPM developmentExecution stage of TPMStep 6. TPM kick off:The purpose of TPM CASE STUDY OF TPM IMPLEMENTATION(CONT)

12 STEPS OF TPM IMPLEMENTATION

EXAMPLE FOR FAILURE MODE ANALYSIS OF TPM MODEL

TANGIBLE BENEFITS FOR TPM IMPLEMENTATIONMean unit between assists (MUBA). Number of improvements. Number of one-point lesson (OPL). Number of suggestions. Training hours for skill level enhancement.IMPROVEMENT IN MUBA THROUGH TPM.

IMPROVEMENT IN MUBA THROUGH TPM. (CONT)

IMPROVEMENT IN MUBA THROUGH TPM. (CONT)

PARETO DISTRIBUTION OF MACHINE STOPPAGES AFTER THE IMPLEMENTATION OF TPM.

SUGGESTION, IMPROVEMENT (KAIZEN), TRAINING During the TPM implementation period, operator and technician were trained and developed with skills and knowledge in maintenance.This was the aim of TPM to train people to be highly skilled, motivated and self-reliant regarding knowhow of their equipment and process.SUMMARY OF TPM IMPLEMENTATIONEffective equipment management: There was about 83% improvement in equipment productivity improvement after TPM implementation. Also, the equipment stoppage rate was reduced from 517 to 89 times. This tremendous improvement enhanced the equipment in both effectiveness and quality in product produced.Empowerment of employees: Empowering the workforce caused a development of a bright, cheerful and relaxed workplace for production people. Growth of work habits, technical skill development and promotion of cross-functional team created an enthusiastic workforce to enhance the company in both competitive power and image.IMPLICATIONS OF THIS STUDYThis case study employed TPM methodology to improve equipment effectiveness as well as the technical skills, morale of members participated in TPM. This was not the first attempt that the company in this study implemented TPM but, ultimately, the company succeeded to do so in the front-end process.THANK YOU