An Introduction to Total Productive Maintenance (TPM)By Arpit Mishra M.Tech. HSER-080209003

Objectives

•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.”

Contents• What is TPM• Why TPM• TPM History• TPM Objectives• Similarity and difference between TPM and TQM• Types of Maintenance• Pillars of TPM• Benefits of TPM• Major Losses• Conclusion• References

TPM: TOTAL PRODUCTIVE MAINTENANCE

T: TOTAL   Participation of all Employees. Covers all Departments. Cover all 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 • Maintenance is not only to repair and maintain the

machines.• To improve the efficiency of the equipment.• Maintenance covers the entire life cycle of the production

system.

Why TPM

•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.

TPM - History

•TPM is a innovative Japanese concept•Origin of TPM can be traced back to 1951 •Nippondenso was the first company to

introduce plant wide preventive maintenance in 1960

Objectives

• 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.•To maintain the HSE conditions of plant and

equipments.•To fulfill Regulatory compliances.

Similarities and differences between TQM and TPM

•Total commitment of upper level management.

•Employees must be empowered to initiate corrective action.Category TQM TPM

ObjectQuality ( Output and effects )

Equipment ( Input and cause )

Mains of attaining goal

Systematize the management. It is software oriented

Employees participation and it is hardware oriented

Target Quality for PPMElimination of losses and wastes.

Types of maintenance

Planned Maintenanc

e

Routine Maint.

Preventive Maint.

Scheduled or fixed

Time Maint.

Condition Based Maint.

Predictive Maint.

CBM or CBMs

Proactive Maint.

Many Strategies

as per need

Maintenance

Unplanned Maintenanc

e

Reactive Maintenanc

e

Breakdown or

Emergency Maint.

Corrective Maint.Opportunisti

c Maintenanc

e

TPM TargetsP

Obtain Minimum 80% OPE.Obtain Minimum 90% OEE ( Overall Equipment Effectiveness )

Run the machines even during lunch. ( Lunch is for operators and not for machines ! )

Q Operate in a manner, so that there are no customer complaints.

C Reduce the manufacturing cost by 30%

D Achieve 100% success in delivering the goods as required by the customer.

S Maintain a accident free environment.

M Increase the suggestions by 3 times. Develop Multi-skilled and flexible workers

Benefits of TPM

•Increased Employee Morale• Increased Productivity•Improved Product Quality•Improved Customer Satisfaction•Reduced Costs•Improved Delivery Time•Enhanced safety Records•Improved Image•Improved Reputation

Major losses in a organization• Failure losses - Breakdown loss• Setup / adjustment losses• Cutting blade loss• Start up loss• Minor stoppage / Idling loss.• Speed loss - operating at low speed• Defect / rework loss• Scheduled downtime loss

Cont………..

•Management loss•Operating motion loss•Line organization loss•Logistic loss•Measurement and adjustment loss

•Energy loss•Die, jig and tool breakage loss•Yield loss.

Conclusion

•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 operation and area safer.

Recommendation

•Proper rest should be given to worker after the shift.

•Provide gifts to the employee to increase the morale .

•Provide Safe working condition.

References• www.plant-maintenance.com• www.maintenanceresources.com• www.reliableplant.com• www.key-tosteel.com• www.evi.org• Maintenance Planning Control & Documentation By E.N. White Gower Press U.K.• Maintainability By B.S. Blanchard, D. Verma, & E.L. Peterson John Wiley & Sons, N.York 1995• Maintenance engineering and management By S.K.Srivastava S.Chand publication First edition 1998 Reprint 2007