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TPM- total productive maintenance
- 1. Emirates Steel Presentation © Emirates Steel 1 TPM-Total Productive Maintenance Asif Iqbal Jan Mohd Electrical & Automation engineer
- 2. Emirates Steel Presentation © Emirates Steel 2 TPM-Total Productive Maintenance Evolution of TPM It is Japanese Approach for • Creating company culture for maximum efficiency • Striving to prevent losses with minimum cost – Zero breakdowns and failures, Zero accident, and Zero defects etc. • The essence of team work (small group activity) focused on condition and performance of facilities to achieve zero loss for improvement • Involvement of all people from top management to operator
- 3. Emirates Steel Presentation © Emirates Steel 3 TPM-Total Productive Maintenance History of TPM TPM is a innovative Japanese concept which can be traced back to 1951. However the concept of preventive maintenance was taken from USA. Nippondenso was the first company to introduce plant wide preventive maintenance in1960. Nippondenso which already followed preventive maintenance also added Autonomous maintenance done by production operators. Preventive maintenance along with Maintenance prevention and Maintainability Improvement gave birth to Productive maintenance. By then Nippon Denso had made quality circles, involving the employees participation. Thus all employees took part in implementing Productive maintenance.
- 4. Emirates Steel Presentation © Emirates Steel 4 TPM-Total Productive Maintenance History of TPM • TPM first introduced in Japan 20+ years ago and rigorously been applied in past 10 years • TPM planning & implementation in Japanese factories supported by JIPM (Japan Institute of Plant Maintenance) • Awarded yearly prizes to various industries: Automotive Metals Chemicals Rubber Food Glass etc. Initially implemented in high-to-medium volume production areas • Later successfully applied in: Low-volume production, High-to-low volume assembly Development areas, Warehouses. Whole range of industry
- 5. Emirates Steel Presentation © Emirates Steel 5 TPM-Total Productive Maintenance EVALUATION OF TPM
- 6. Emirates Steel Presentation © Emirates Steel 6 TPM-Total Productive Maintenance What is TPM ?
- 7. Emirates Steel Presentation © Emirates Steel 7 TPM-Total Productive Maintenance What is TPM ? T Total Overall Effiency Total Production System. Participation of all employees. P Productive Zero Defect Continues Production. Safety M Maintenance Longer Life cycle of Production System.
- 8. Emirates Steel Presentation © Emirates Steel 8 TPM-Total Productive Maintenance Why is TPM so popular and important ? Three main reasons: 1. It guarantees dramatic results (Significant tangible results) • Reduce equipment breakdowns • Minimize idle time and minor stops • Less quality defects and claims • Increase productivity • Reduce manpower and cost • Lower inventory • Reduce 2. Visibly transform the workplace(plant environment) • Through TPM, a filthy, rusty plant covered in oil and grease, leaking fluids and spilt powders can be reborn as a pleasant and safe working environment • Customers and other visitors are impressed by the change • Confidence on plant’s product increases 3. Raises the level of workers knowledge and skills As TPM activities begin to yield above concrete results, it helps: • The workers to become motivated • Involvement increases • Improvement suggestions proliferate • People begin to think of TPM as part of the job
- 9. Emirates Steel Presentation © Emirates Steel 9 TPM-Total Productive Maintenance
- 10. Emirates Steel Presentation © Emirates Steel 10 TPM-Total Productive Maintenance
- 11. Emirates Steel Presentation © Emirates Steel 11 TPM-Total Productive Maintenance
- 12. Emirates Steel Presentation © Emirates Steel 12 Maintenance Approach TPM-Total Productive Maintenance
- 13. Emirates Steel Presentation © Emirates Steel 13 TPM-Total Productive Maintenance 5S
- 14. Emirates Steel Presentation © Emirates Steel 14 TPM-Total Productive Maintenance
- 15. Emirates Steel Presentation © Emirates Steel 15 TPM-Total Productive Maintenance
- 16. Emirates Steel Presentation © Emirates Steel 16 TPM-Total Productive Maintenance
- 17. Emirates Steel Presentation © Emirates Steel 17 TPM-Total Productive Maintenance Identification of Major Losses
- 18. Emirates Steel Presentation © Emirates Steel 18 TPM-Total Productive Maintenance
- 19. Emirates Steel Presentation © Emirates Steel 19 TPM-Total Productive Maintenance What is OEE? Overall Equipment Efficiency OEE = A x P x Q A= Availability P= Performance Q= Quality How to Calculate OEE? Availability = Standard time – downtime Standard time Performance = Components Produced Components supposed to be Produced Quality = Total Acceptable Components Total Components produced
- 20. Emirates Steel Presentation © Emirates Steel 20 Thank you Asif.jan@emiratessteel.com