What is Total ProductiveMaintenance?• TPM is a plant improvementmethodology which enables continuousand rapid improvement of themanufacturing process through use ofemployee involvement, employeeempowerment, and closed-loopmeasurement of results
• TOTAL = All encompassing bymaintenance and productionindividuals working together• PRODUCTIVE = Production goods andservices that meet or exceedcustomers’ expectations• MAINTENANCE = Keeping equipmentand plant in as good as or better thanthe original conditions at all timesBreakdown of TPM
TPM - History• Productive maintenance (PM) originated inthe U.S. in late 1940’s & early 1950’s• Japanese companies modified and enhancedit to fit the Japanese industrialenvironment• The first use the term TPM was in 1961 byNippondenso, a Japanese auto componentsmanufacturer• Seiichi Nakajima – head of JIPM, one ofthe earliest proponents, known as theFather of TPM
Goals of TPM1. Aims at getting the most effective use ofequipment2. Builds a comprehensive PM system3. Brings together people from all departmentsconcerned with equipment4. Requires the support and cooperation ofeveryone from top managers down5. Promotes and implements PM activities basedon autonomous small group activities.6. Maintaining Equipment for life7. Encouraging input from all employees8. Using teams for continuous improvement
Three Principles of Prevention• Maintenance of normal conditions• Early discovery of abnormalities• Prompt response
Launching TPM- Preparatory Stage• Announce top management’s decisionto introduce TPM• Launch an educational campaign tointroduce TPM• Create an organizational structure topromote TPM• Establish basic policies• Form a master plan for implementingTPM
• Improve the effectiveness of each criticalpiece of equipment• Set up and implement autonomousmaintenance• Establish a planned maintenance system inthe maintenance department• Provide training to improve operator andmaintenance skills• Develop an early equipment managementprogramLaunching TPM- TPM Implementation
• Perfect TPMimplementation and raiseTPM levelsLaunching TPM- Stabilization
TPM - Benefits• Improved equipment eliminates the root cause ofdefects• Defects are prevented through plannedmaintenance• Preventive maintenance costs are reduced asequipment operators conduct autonomousmaintenance• Improved equipment designs ensure that newequipment naturally produces fewer defects• Simplified products designs and a redesignedprocess produce with few defects• Engineers, technicians and managers are trained inmaintenance and quality
TPM - Benefits(Japanese TPM Prize winners during 1982-1984)• Equipment failures reduced from1,000/month to 20/month• Quality defects reduced from 1.0% to 0.1%• Warranty claims reduced by 25%• Maintenance costs reduced by 30%• WIP decreased by 50%• Productivity improved by 50%. (Patterson &Fredendall, 1995)
TPM – Success stories• USPS Albany, New York: annual save of$86,000; could save $4.5 million if appliednationwide• Yamato Kogyo Corp., Japan:- productivity up by 130%,- accidents cut by 90%,- defects reduced by 95%,- employee suggestion rate increased byover 300%
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