This document discusses Total Productive Maintenance (TPM), which aims to maximize equipment effectiveness through the involvement of all employees. It outlines the history and objectives of TPM, as well as its eight pillars: 5S, Autonomous Maintenance, Focused Improvement, Planned Maintenance, Quality Maintenance, Training, Safety and Health, and Office TPM. Implementing TPM through these pillars can provide benefits such as increased productivity, improved quality, reduced costs, and enhanced employee morale and job satisfaction.

1. Total Productive
Maintenance
TERM ASSIGNMENT
Subject:- Maintenance Engineering
and Asset Management
Semester:- 5th sem –A Division
Submitted by:- 19bme506 Gohel Yash
19bme508 Jain Harshit

2. Outline
 Introduction: What isTPM?
 History of TPM
 Why TPM
 TPM objectives
 Benefits of TPM
 Types of maintenance
 TPM Targets
 Major Losses in Production Line and Organization
 Pillars of TPM
Pillar 1: 5S
Pillar 2: Jıshu Hozen
Pillar 3: Kobetsu Kaizen
Pillar 4: Planned Maintenance
Pillar 5: Quality Maintenance
Pillar 6: Training
 Conclusion
 References

3. TPM
 TPM is a Japaneseconcept
 Origin of TPM can be traced back to1951, a company that created parts for
Toyota.
 TPM benchmark developed by the JIPM Seiichi Nakajima is therefore
regarded as the father of TPM.
 Total:
 Participant of all employee.
 Include all Departments, operation, equipment and
process.
 Productive:
 Pursue maximum efficiency of the production system by making zero loses.
 Maintenance:
 It means to proper maintain machine for good and productive life cycle

4. Why TPM ?
1. The major difference between TPM and other concepts is that the operators are
also made to involve in the maintenance process.
2. Avoid wastage in quickly changing environment.
3. Reduce Cost of Manufacturing.
4. Produce a batch quantity at the earliest possible time.
5. Goods send to Customers must be “ non – defective”
TPM Objectives
1. Increase production while, at the same time, increasing employee morale and job
satisfaction.
2. Hold emergency & unscheduled maintenance to a minimum.
3. Toprovide the safe and good working environment to the worker.
4. Achieve Zero Defects, Zero Breakdown and Zero accidents in all functional
areas of the organization.
5. Involve people in all levels of organization.
6. Form different teams to reduce defects and Self
Maintenance.
7. Tomaintain the HSE conditions of plant and equipment's.

5. Benefits of TPM
 Increased Employee Morale
 Increased Productivity
 Improved Sharing and Working as a Team
 Improved tidines and cleaning of the working place
 Improved Product Quality
 Improved Customer Satisfaction
 Reduced Costs
 Improved Delivery Time
 Enhanced safety Records
 Improved Image
 Improved Reputation

6. Major Losses in Production Line and
Organization
• Failure losses – Breakdown loss
• Setup / adjustment losses
• Cutting blade loss
• Start up loss
• Minor stoppage / Idling loss.
• Speed loss - operating at low speed
• Defect / rework loss
• Scheduled downtime loss
•Management loss
•Operating motion loss
•Line organization loss
•Logistic loss
•Measurement and
adjustment loss
•Energy loss
•Die, jig and tool breakage
loss
•Yield loss

7. Pillars of TPM

8. SEIRI – SORTOUT: Keep only essential items and eliminate what is not
required, prioritizing things as per requirements and keeping them in
approachable places. Everything else is stored or discarded.
SEITON – ORGANIZE:There should be a place for everything and
everything should be in its place. Each tool, part, supply, or piece of
equipment should be kept close to where it will be used – in other
words, straightening the flow path.
SEISO – SHINE THE WORKPLACE:Keep the workplace tidy and
organized. At the end of each shift, clean the work area and be sure
everything is restored to its place.
SEIKETSU – STANDARDIZATION: Work practices should be
consistent and standardized. Everyone should know exactly what his
or her responsibilities are for adhering to the first 3 S's.
SHITSUKE – SELF DISCIPLINE: When an issue arises such as a
suggested improvement, a new way of working, a new tool or a new
output requirement, review the first 4 S's and make changes as
appropriate.
Pillar1 : 5 S

9. PILLAR 2 :JISHU HOZEN
(autonomous maintenance)
“Jishu-Hozen” means activities of the operator that uses maintenance to personally
conduct maintenance activities, including cleaning, oiling, retightening, and
inspection, thereby raising production efficiency to its limit. Such activities will
prevent forced deterioration of equipment.
JISHU HOZEN TARGETS
1. Reduce process time by predicted values
2. Reduce oil/ lubricants consumption by predicted values
3. Increase use of JH

10. PILLAR 3 : KOBETSU KAIZEN
 KAI means change or improvement and
 ZEN means good (for the better).
 Kobetsu means focused. Basically
 Kobetsu Kaizen is for small adjustments and corrections but effects the whole
process and carried out on a continual basis and involves all people in the
organization.
This pillar is aimed at :
 Reducing losses in the work placethat affect our efficiencies.
 By using a detailed and through procedure, eliminate losses in a
systematic method using various Kaizen Tools.

11. Pillar 4: Planned Maintenance
 Planned maintenance refers to any maintenance activity that is planned, documented,
and scheduled. The aim of planned maintenance is to reduce downtime by having all
necessary resources on hand, such as labour and parts, and a strategy to use these
resources
Policy:
 Achieve and sustains availability of machines
 Optimum maintenance cost.
 Reduce spares inventory.
 Improve reliability and maintainability of machines.
Steps and Target:
 Equipment evaluation and recording presentstatus.
 Restore deterioration and improve weakness.
 Building up information management system.
 Prepare time based information system, select equipment, parts and members
and map on theplan.
 Prepare predictive maintenance system byintroducing equipment diagnostic
techniques and
 Evaluation of planned maintenance.

12.  It is aimed towards customer delight through highest quality through defect free
manufacturing. Focus is on eliminating non-conformances in a systematic manner.
 Quality defects are classified as “CUSTOMER END defects” and “IN HOUSE
defects”.
 For customer-end data, we have to get data on Customer-end line rejection and
field complaints. In-house data include data related to products and data related to
process.
POLICY:
◦ Defect free conditions and control of equipment's
◦ QM activities to support quality assurances.
◦ Focus of prevention of defects at source
◦ Focus on precaution (Pokayoke) system.
◦ In-line detection and segregation of defects.
◦ Effective implementation of operator quality assurance.
TARGET:
Achieve and sustain customer complaints at zero. Reduce in-process
defects by 50%.
Reduce cost of quality by 50%.
Pillar 5: Quality Maintenance

13. Pillar 6: Training
 It is aimed to have multi-skilled revitalized employees whose moral is high and
who has eager to come to work and perform all required functions effectively and
independently.
Education is given to operators to upgrade their skill.
 The employees should be trained to achieve the form phase of skill which are
as under:
PHASE 1: Do not know.
PHASE 2: Know the theory but cannot do.
PHASE 3: Can do but cannot teach.
PHASE 4: Can do and also teach.
STEPS IN TRAINING
1. Setting policies and priorities and checking present status of education and
training.
2. Establish of training system for operations and maintenance skill up gradation.
3. Training the employees for up gradation the operation and maintenance
skills.
4. Preparation of training calendar.
5. Evaluation of activities and study of future approach

14. Pillar 7: Tpm Office
 Office TPM should be started after activating from other pillars of TPM (JH, KK,
and QM.PM).
 Office TPM must be established to improve productivity, efficiency in the
administrative function and identify eliminate losses.
 This includes analyzing process and procedure towards increased office
automation. Statistical analysis will give higher effectiveness to investigate the
production and management departments simultaneously.
 Tpm office has responsibility to take the report of the losses and gainings then
scheduling the traning hours professional trainers for the entire company.

15. References
 https://leanfactories.com/tpm-pillars-eight-pillars-of-total-
productive-maintenance/
 www.plant-maintenance.com
 www.maintenanceresources.com
 www.key-tosteel.com
 https://www.graphicproducts.com/articles/tpm-
implementation/
 https://en.wikipedia.org/wiki/5S_(methodology)
 https://www.leanproduction.com/tpm.html