Total Productive Maintenance

Total Productive maintenance(TPM)

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Total Productive maintenance(TPM)

What is TPM?:
What is TPM? Medical science of machines Newly defined concept for maintaining plants and equipment Brings maintenance into focus as a necessary and vitally important part of the business. 3

Why TPM?:
Why TPM? TPM was introduced to achieve the following objectives. Avoid wastage in a quickly changing economic environment. Producing goods without reducing product quality. Reduce cost Produce a low batch quantity at the earliest possible time. Goods send to the customers must be non defective. 4

TPM - History:
TPM - History Total productive maintenance (TPM ) was introduced in Japan since 1951. Nippondenso was the first company to introduce plant wide preventive maintenance in 1960. Based on the developments Nippondenso was awarded the distinguished plant prize for developing and implementing TPM, by the Japanese Institute of Plant Engineers ( JIPE ). Thus Nippondenso of the Toyota group became the first company to obtain the TPM certification. 5

Types of maintenance:
Types of maintenance 1. Breakdown maintenance People wait until equipment fails and then repair it. 2. Preventive maintenance Daily maintenance like cleaning, inspection, oiling and re-tightening. Periodic maintenance ( Time based maintenance - TBM) Predictive Maintenance (condition based ) 6

Types of maintenance:
Types of maintenance 3. Corrective maintenance It improves equipment and its components so that preventive maintenance can be carried out reliably. 4. Maintenance prevention It indicates the design of a new equipment Weakness of current machines are sufficiently studied and incorporated before commissioning a new equipment. 7

TYPES OF WASTE:
TYPES OF WASTE 8

Types of waste:
Types of waste 1 st Waste : 9

Types of waste:
Types of waste 2 nd Waste : 10

Types of waste:
Types of waste 3 rd Waste : 11

Types of waste:
Types of waste 4 th waste : 12

Types of waste:
5 th Waste : Types of waste 13

Types of waste:
Types of waste 6 th Waste : 14

Types of waste:
Types of waste 7 th Waste : 15

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5 S:
5 S SEIRI – Sort out Eliminate cluster Remove unwanted materials - regularly Develop clear policy SEITON – Set in order A place for every thing and every thing in its place Arrange everything in a way you can retrieve quickly Frequently used items should be stored for easy retrieval 18

5 S:
5 S SEISO – shine the workplace Cleaning the workplace – free of bugs, grease, scrap etc. No loosely hanging wires or oil leakage from machines. SEIKETSU – standardize Develop and maintain standard conditions in the work place Decide when, by whom and how each item should be used Standardise quantities for all items for storage and movement SHITSUKE – Sustain Develop self discipline Make 5S a part of daily routine Conduct 5S audits 19

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PILLAR 1:
PILLAR 1 This pillar is geared towards developing operators to be able to take care of small maintenance tasks. The operators are responsible for upkeep of their equipment to prevent it from deteriorating. It prepares operators to be active partners with maintenance and engineering personnel in improving the over all performance and reliability of equipment. 21

Steps in Jishu Hozen:
Steps in Jishu Hozen Preparation of employees – Train and educate the employees about TPM Train about JH advantages and steps Initial cleanup of machines Setting a date for implementing step 1 Arranging all items needed for cleaning Problems being suitably categorized & tagged 22

Steps in Jishu Hozen:
Steps in Jishu Hozen Counter Measures Inaccessible regions has to be reached easily. Machine parts should be modified to prevent accumulation of dirt and dust. Tentative standard JH schedule has to be made and followed strictly Schedule to be made regarding cleaning, lubrication, inspection etc. Autonomous inspection New methods Employee prepares his own autonomous chart/schedule Frequency of cleanup and inspection is reduced based on experience. 23

Steps in Jishu Hozen:
Steps in Jishu Hozen Standardization In this step the surroundings of machinery are organized. Work environment is modified such that there is no difficulty in getting any item Autonomous Management PDCA ( Plan, Do, Check and Act ) cycle must be implemented for Kaizen. 24

PILLAR 2:
PILLAR 2 Kaizen is for small improvements, but carried out on a continual basis and involve all people in the organization. " Kobetsu " means individual or focused. This pillar is aimed at reducing losses in the workplace that affect our efficiencies. Kobetsu Kaizen attempts to improve the Overall Equipment Effectiveness (OEE) of a machine by eliminating one type of loss at a time until all the losses are eliminated Kobetsu Kaizen 25

Kobetsu Kaizen :
Loss Category Failure Losses – Breakdown Loss Setup / adjustment losses Cutting Blade loss Start up loss Minor stoppage / Idling Loss. Speed loss – Operating at low Speeds. Defect / rework loss Scheduled downtime loss Losses that impede equipment efficiency 9. Management loss 10. Operating motion loss 11. Line Organization loss 12. Logistic loss 13. Measurement and Adjustment loss Losses that impede human work efficiency 14. Energy loss 15. Die , jig and tool breakage loss 16. Yield loss. Losses that impede effective use of Production resources 16 Major losses in a organisation: Kobetsu Kaizen 26

PILLAR 3 - Early / Development Management:
PILLAR 3 - Early / Development Management Early Management is a procedure to critically review an equipment or process at the design stage itself. Following facts are achieved by Early management : Optimize life cycle costs Trouble free plant commissioning after construction Trouble free process performance Minimizes – Future maintenance cost Deterioration losses of new equipment 27

PILLAR 4 - Planned Maintenance:
PILLAR 4 - Planned Maintenance Planned Maintenance aimed to have trouble free machines and Equipments producing defect free products for Total customer Satisfaction. This Break maintenance down into 4 Groups:- Preventive Maintenance Breakdown Maintenance Corrective Maintenance Maintenance Prevention 28

Six steps in Planned maintenance : :
Six steps in Planned maintenance : 1.Equipment evaluation and recoding present status. 2.Reverse deterioration and improve weakness. 29

Six steps in Planned maintenance :
Six steps in Planned maintenance 3. Building up information management system. 4.Prepare time based information system, select equipment, parts and members and map out plan. 5. Prepare predictive maintenance system by introducing equipment diagnostic techniques 6. Evaluation of planned maintenance. 30

PILLAR 5:
PILLAR 5 It is aimed towards customer delight through highest quality through defect free manufacturing. Focus is on eliminating non-conformances in a systematic manner, much like Focused Improvement. QM activities is to set equipment conditions that preclude quality defects, based on the basic concept of maintaining perfect equipment to maintain perfect quality of products. 31

Quality Maintenance:
Quality Maintenance Steps in practicing Quality Maintenance : Prepare QA matrix Prepare production - input condition analysis table Prepare problem chart Evaluate seriousness of problems Use PM analysis to track down causes of problems Assessing impactsof the countermeasures Implement improvements Review production - input conditions Consolidate and confirm checkpoints Prepare a quality component control table and assure quality through strict condition control 32

PILLAR 6 - OFFICE TPM:
PILLAR 6 - OFFICE TPM

Office TPM:
Office TPM Office TPM brings improvements in office areas In Office TPM, the office is oriented to provide excellent support for Operations. Office systems are effectively organized. Wastages are eliminated. The Office TPM involves practice of :- Administrative Focused Improvement. Administrative Autonomous Maintenance. Performance Measurement. 34

Office TPM:
Office TPM Administrative Focused Improvements Clarify the Subjects Identify Relationships and isolate Problems Identify and Prioritize improvement topics Formulate basic improvement concept Implementing those Improvement. Administrative Autonomous Maintenance Do Initial cleaning and stocktaking Identify and address Problems Prepare Standards and Manuals Educate and Train Perform General Inspection Established full self-management 35

Office TPM:
Office TPM Performance Measurement Cost Effectiveness. Functional efficiency. Creativity. 36

PILLAR 7- Education & Training of TPM:
PILLAR 7- Education & Training of TPM 37

Education & Training:
Education & Training Education & Training pillars establishes education and training system designed to maximize potential of employees. Education is given to operators to upgrade their skill. It is not sufficient to know only "Know-How" but they should also learn "Know-why“ i.e Employee should know why they are doing so. The employees should be trained to achieve 1 : Do not know. 2 : Know the theory but cannot do. 3 : Can do but cannot teach 4 : Can do and also teach. 38

Steps in Educating and Training:
Steps in Educating and Training Evaluate the current training program and set policy and priority strategies. Design a program for improving operating and maintenance skills Implement operating and maintenance skills training Design and develop a skill development system Foster an environment that encourages self-development Evaluate the activities and plan for the future. 39

PILLAR 8:
Safety Management Environment Management Zero Accident Zero Injury Zero Pollution Zero Waste PILLAR 8 40

Safety, Health & Environment:
Safety, Health & Environment Safety, Health and Environment has procedures focused on equipment processes and people, towards achieving zero accident and zero health hazards. To eliminate accidents and pollution, specific steps are taken to strengthen the organization and management of both people and equipment. Zero accident. Zero health damage Zero fires. In this area focus is on to create a safe workplace and a surrounding area that is not damaged by the process or procedures. This pillar will play an active role in each of the other pillars on a regular basis. 41

Safety, Health & Environment:
Safety, Health & Environment Steps to eliminate accidents and pollution Established basic safety requirement Develop equipment and Process competent people Consolidation 42

IMPACT OF TPM:
IMPACT OF TPM

Effectiveness of TPM in industry:
Effectiveness of TPM in industry Effectiveness of TPM is reflected by improvement in P – Productivity enhancement Target - Obtain Minimum 80% OPE(Overall Plant Effectiveness) Obtain Minimum 90% OEE ( Overall Equipment Effectiveness ) Q - Quality improvement C – Cost Control D – Delivery in time S – Safety M- Morale 44