TPM Basics

Total Productive
Maintenance & Its Pillars
https://www.linkedin.com/in/tqmbala/ tqmbala@gmail.com

Total Productive Maintenance
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eph;zapj;j cw;gj;jp ,yf;if miltjw;fhd [g;ghdpa top;KiwiaNa
TPM vd;fpNwhk;.
 ,jid mwpKfg;gLj;jpath; Seiichi Nakajima vd;w [g;ghdpah; Mthh;.
 TPM is a holistic approach to equipment maintenance that strives to achieve
perfect production : No Breakdowns. No Small Stops or Slow Running.
 It is the process of maximizing equipment effectiveness through
the active involvement of all supporting departments.
1919 - 2005

Total Productive Maintenance
Total
Participation of All employees
Maximization of Overall Equipment Efficiency
Productive
Increasing the Productivity of machines
Elimination of Losses
Maintenance Improving the Efficiency and Availability of assets

Goals of TPM
TPMd; ,yf;Ffs;
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ZERO

TPM Pillars - TPM Jhz;fs;
5S SYSTEM
1.Focused Improvement
2.Autonomous Maintenance
3.Planned Maintenance
4.Quality Maintenance
5.Education & Training
6.Early Equipment Management
7.Health, Safety & Environment
8.Office TPM
5S SYSTEM

Foundation of TPM
5S SYSTEM
 TQM, TPM, TPS kw;Wk; Lean vd midj;jpw;Fk; 5S KiwNa mbj;jsk; MFk;.
 5S Kiwia eilKiwg;gLj;jhky; Nkw;fz;l vjidAk; ntw;wpfukhf
eilKiwg;gLj;j KbahJ.
 vdNt jhd; “5S is the gateway to improvement” vd miof;fg;gLfpwJ.
TPM-d; mbj;jsk;

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cz;lhFk; ,og;Gfisf; fz;lwpe;J mfw;Wk; Kiw.
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Njitahd eltbf;if vLj;jy; kw;Wk; KbTfis njhlh;e;J fz;fhdpg;gij
cs;slf;fpaJ.
 Focused Improvement aims to identify and eliminate losses through the use of a
structured problem-solvingprocess.
 It involves analyzing data, identifying root causes of problems, implementing
correctiveactions, and continuouslymonitoringthe results.
Focused Improvement - TPM

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Mg;gNul;liuNa rhh;e;jpUf;fhky;> nkrpd; Mg;gNul;lh;fNs mth;fs; gzpGhpAk;
nkrpd;fis jpdrhp fz;fhdpj;J Njitahd rpW> rpW guhkhpg;G Nkw;nfhs;tjd;
%yk;> nkrpdpd; nray;jpwid Nkk;gLj;Jk; Kiw.
 ,jdhy; gOJ> cw;gj;jp ,og;G> Ntiyr;Rik> nryT Mfpadtw;iw Fiwf;f KbAk;.
 Autonomous maintenance means that machine operators are responsible for the
basic maintenance tasks, rather than relying on dedicated maintenance
technicians.
Example :
 Lubrication, Bolt tightening, Cleaning, Safety checks and Inspections
Autonomous Maintenance - TPM

Example :
Preventive maintenance involves changing the oil at regular
intervals, such as every 3,000 miles, to ensure the vehicle's
engine functions optimally..
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gzpfis jpl;lkpl;L Nkw;nfhs;Sjy;.
 ,jdhy; vjph;ghuhj gOJfis Fiwj;J cw;gj;jp ,og;G kw;Wk; nryTfisf;
Fiwf;fyhk;;.
 Planned Maintenance focuses on preventing equipment failures through regular
maintenanceactivitiessuch as cleaning, lubrication, and inspection.
 It involves creating a maintenance schedule, conducting routine maintenance
checks, and addressingany issues beforethey become major problems.
Planned Maintenance - TPM

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 ,J gpur;rpidf;fhd fhuzq;fs;> %yfhuzq;fisf; fz;lwpjy;> juTfis
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%yk; KOikahd juk; thbf;ifahsUf;F toq;fg;gLtij cWjpnra;fpwJ.
 Quality Maintenance aims to prevent product defects and reduce variability.
 It involves identifying and fixing quality problems, analyzing data to find the
root causes, and continuously monitoring the results to ensure high-quality
products are delivered to customers.
Quality Maintenance - TPM

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epWtdj;jpd; ntw;wpf;F gq;fspg;gjw;Fk; Njitahd mwpT kw;Wk; jpwd;fs;
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jpwd;fis Nkk;gLj;Jtjw;fhd gapw;rpfis cs;slf;fpaJ.
 Education & Training ensures that all employees have the necessary knowledge
and skills to perform their jobs effectively and contribute to the success of the
organization.
 It involves offering training programs to enhance technical skills, safety
awareness, and problem-solving abilities. It also includes promoting a culture of
continuouslearningand improvement.
Education & Training - TPM

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kw;Wk; epWTjypy; ftdk; nrYj;Jjy;.
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Ntiy topKiwfis tFj;jiy typAWj;JfpwJ.
 Early Equipment Management focuses on improving equipment reliability and efficiency
from the design phase.
 It involves working closely with equipment manufacturers, engineers, and production
teams to ensure that new equipment is reliable, easy to maintain, and meets production
requirements.
 It also includes developing procedures and standards for equipment installation, testing,
and commissioning.
Example :
Selecting machineries / cars based on the available
infrastructure/space.
Early Equipment Management - TPM

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 ,J mghaq;fis fz;lwpjy;> jLg;G eltbf;if vLj;jy;> ghJfhg;G rhh;e;j gapw;rp
toq;Fjy; kw;Wk; Rw;Wr;#oiy fz;fhdpj;J njhlh;e;J Nkk;gLj;Jtij
cs;slf;fpaJ.
 Emphasizes the importance of maintaining a safe and healthy work environment
for all employees, as well as minimizing environmental impact.
 It involves identifying potential hazards, implementing preventive measures,
providing training to employees, and continuously monitoring and improving
safety and environmentalperformance.
 The goal is to ensure a sustainable and responsible workplace.
Health, Safety & Environment - TPM

Office TPM / TPM in Administration
 TPM topKiwfis cgfuz Nkyhz;ikf;F kl;Lkpd;wp> mYtyfj;jpy;
eilKiwg;gLj;Jtjd; %yk;> tpuaq;fis Fiwj;;jy;> gpiofis jtph;j;jy;
kw;Wk; mYtyf gzpg;gFg;gha;Tfis Nkk;gLj;Jjy; vd epWtdj;jpd;
nray;jpwid mjpfhpf;f ,J cjTfpwJ.
 Office TPM is an extension of the Total Productive Maintenance (TPM) system
that applies the same principles of equipment maintenanceto officeprocesses.
 It involves improving office processes and workflows to eliminate waste, reduce
errors, and increaseproductivity.
 The goal is to create a more efficient and streamlinedoffice environment.

For more Lean, TQM related training Materials…
- 5S BALAMURUGAN
BSc(CS).,MBA(HR,TQM).,MA(PM&IR).,MSc(Psy).,
Lean Practitioner | Quality Management Trainer | HR Professional
https://www.slideshare.net/BalaMurugan272

TPM Basics

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