Total Productive Maintenance (TPM) is a method for involving machine operators in the preventive maintenance of their machines to improve reliability and reduce breakdowns. The objectives of TPM are to eliminate losses like downtime, defects, and accidents in order to improve safety, quality, and financial performance. TPM aims for concept zero - zero accidents, defects, and breakdowns - through autonomous maintenance by operators and predictive maintenance techniques. It works by categorizing different types of maintenance and establishing pillars like focused improvement, planned maintenance, and education and training to drive waste to zero.

1. Total Productive
Maintenance
ISYE650 Class Presentation
Spring 2014
By Akhil Yelisetti

2. TPM overview
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T P M
Total Productive
Maintenance
What’s TPM
How TPM
works
Concept Zero
TPM Targets
Why TPM
Objectives of
TPM

3. What’sT P M
• TPM wasdeveloped in the 1970's as amethodof involving
machineoperators in the preventive maintenanceof their
machines
– a reaction to increasing specialization and centralization of the maintenance
function that had createddivision-of-labor barriers between operators and the
maintenance of their machines and equipment.
– Also creating a sense of ownership in workers with Autonomous Maintenance
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4. Objectives ofT P M
• Theoverriding objective of TPMis the elimination ofLOSSES.Losses, or
waste, includes equipment downtime, defects, scrap, accidents, wasted energy,
and labor inefficiency.
• TPM was introduced to achieve some of the following important objectives:
– Safer working environment, Job security
– Producing goods with improved quality and machinereliability
– Improved financial performance
– Producea low batch quantity at the earliest possible time.
– Goods send to the customers must benon defective
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5. Why T P M
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Before 1 Severe problem occured, there were 300 minor and 29 major problems to
handle.
Source: Kaizen Institute, Frankfurt
Heinrich‘s Law
TPM is a tool which addresses potential signs of machine break-downs and is therefore
an important instrument to prevent total machine crashes.
1
29
300
Severe problem
Minor problems
Major problems

6. Concept ZERO
• Thegoal ofTPMisto driveall wasteto zero: ZeroAccidents,Zero
Defects,ZeroBreakdowns.
• The Concept of Zero is built uponPoka-Yoke, in the design of the process to make
it impossible to makeand pass on defects.
• Poka-Yoke concepts are also commonlyapplied to equipment to prevent
breakdowns.
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7. Performance Measure and 6 Losses
• OEE is the performance measureof TPM.
• Thus factors affecting OEE/ TPM:
• Availability
• Performance
• Quality
– Associated 6 big losses are:
• Availability Losses: Breakdown losses caused bythe equipment; Set-up
and adjustment losses
• Performance Losses: Minor stoppage losses; Speed losses
• Quality Losses: Quality defect and rework losses; Yield losses
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8. Pillarsof TPM
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9. How it Works
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10. Types ofMaintenance
• BreakdownMaintenance:Thisoccurs when equipment failsbut doesnot affect
production or operationor extracostsother than repairs
• PreventiveMaintenance:A dailymaintenancedesignedto maintainequipment
againstfailingand alsoimprovedhealthcondition
– PeriodicMaintenance:Atimebasedmaintenance
– PredictiveMaintenance:Maintenancebased on condition monitoringby
employingsurveillancesystem
• CorrectiveMaintenance:Redesigningequipmentwith weaknessto improve
reliability
• MaintenancePrevention:Thisindicatesdesignof new machineby Cross
functional teams afterthorough study on weaknessof current machines
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11. TPM Targets
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P roduction:
Obtain Minimum80% OPE.
Obtain Minimum90% OEE( Overall Equipment Effectiveness )
Runthe machineseven duringlunch.( Lunchis for operators and not for machines!)
Quality:
Operate in a manner,so that thereareno customer complaints.
C osts:
Reduce themanufacturingcost by 30%.
D elivery:
Achieve100%success indelivering the goods as requiredby the customer.
Safety:
Maintain a accident freeenvironment.
M aintenance:
Develop Multi-skilled and flexible workers. AndCross functional teams

12. References
• http://www.plant-maintenance.com/articles/tpm_intro.shtml
• http://www.leanproduction.com/tpm.html
• http://technologyinterface.nmsu.edu/fall97/manufacturing/tpm2.html
• https://www.moresteam.com/lean/tpm.cfm
• http://www.epa.gov/lean/environment/methods/tpm.htm
• http://www.slideshare.net/exerciselean/tpm-presentation-
1522308?qid=647eedce-04f7-4ddf-9625-
6acfb0bc419d&v=default&b=&from_search=10
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13. Queries
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