4. 1. What Is TPM
• TPM is a productive maintenance implemented
by all employees in an organization.
• TPM involves everyone in the organization from
operators to senior management in equipment
improvement.
5. 1. What Is TPM
TPM in three words:
T Total • Overall efficiency.
• Total production system.
• Participation of all employees.
P Productive • Zero defect.
• No trouble in operation.
• Safety.
M Maintenance • Longer life cycle of production
system.
7. 2. History of TPM
• This is an innovative Japanese concept.
• Developed in 1951.
• Nippondenso was the 1st company that
implemented TPM in 1960.
• Based on these developments Nippondenso
was awarded the distinguished plant prize for
developing and implementing TPM, by the
Japanese Institute of Plant Engineers ( JIPE ).
• This Nippondenso became the first company
to obtain the TPM certifications.
9. 3. Objective of TPM
• Increase production quality.
• Increase job satisfaction.
• Using teams for continuous improvement.
• Improve the state of maintenance
• Empower employees
11. 3. Principles of TPM
• A Use Overall Equipment Effectiveness (OEE) as a
compass for success.
• Improve existing planned maintenance systems
• Work toward zero losses
• Providing training to upgrade operations and
maintenance skills
• Involve everyone and utilize cross-functional teamwork
12. 3. Principles of TPM
What is OEE
Overall Equipment Efficiency
OEE = A x P x Q
A= Availability
P= Performance
Q= Quality
13. 3. Principles of TPM
How To Calculate OEE
Availability =
Standard time
Standard time – downtime
Performance =
Components Produced
Components supposed to be Produced
Quality =
Total Acceptable Components
Total Components produced
14. 3. Principles of TPM
• Improve existing planned maintenance systems
Types of maintenance
Breakdown maintenance
Preventive maintenance
.periodic maintenance( time based maintenance)
.Predictive maintenance
Corrective maintenance
Maintenance prevention
15. 3. Principles of TPM
Breakdown maintenance
• Repairs or replacements performed after a machine has failed
to return to its functional state following a malfunction or
shutdown.
• e.g., an electric motor of a machine tool will not start, a belt is
broken, etc.
• Under such conditions, production department calls on the
maintenance department to rectify the defect.
• After removing the fault, maintenance engineers do not
attend the equipment again until another failure or
breakdown occurs.
16. 3. Principles of TPM
Preventive maintenance
• The primary goal of preventive maintenance is to prevent the
failure of equipment before it actually occurs.
• It is designed to preserve and enhance equipment reliability
by replacing worn components before they actually fail.
• It is a daily maintenance which includes cleaning, inspection,
oiling and re-tightening of equipments.
17. 3. Principles of TPM
Periodic maintenance (TBM)
• Time based maintenance consists of periodically inspecting,
servicing and cleaning equipment and replacing parts to
prevent sudden failure and process problems.
Benefits:
• Extended life and use of the equipment.
• Reliable production at the times when machine is needed
most.
18. 3. Principles of TPM
Predictive maintenance
• This is a method in which the service life of important part is
expected based on inspection or diagnosis, in order to use the
parts to the limit of their service life.
• Compared to periodic maintenance, predictive maintenance is
condition based maintenance.
19. 3. Principles of TPM
Predictive maintenance
Benefits:
• Increased plant readiness due to greater reliability of the
equipment.
• Many industries report from two to ten percent productivity
increases due to predictive maintenance practices.
• Reduced expenditures for spare parts and labor.
• Reduces the probability of a machine experiencing a
disastrous failure, and this results in an improvement in
worker safety.
20. 3. Principles of TPM
• Work toward zero losses
Type of Losses
1. T- Transportation
2. I- Inventory
3. M-Motion
4. W- Waiting
5. O- Over Process
6. O-Over Production
7. D-Delay
24. 5. Pillars of TPM
2 JISHU HOZEN (AUTONOMOUS MAINTENANCE)
•THIS PILLAR DEVELOPS OPERATOR TO TAKE CARE OF SMALL MAINTENANCE TASKS .
•RESULTING SKILLED MAINTENACE TEAM TO CONCETRATE ON VALUE ADDED AND
TECHNICAL REPAIRS .
•THE OPERATOR RESPONSIBLE FOR UP KEEP OPF THEIR EQUIPMENT TO PREVENT IT
FROM DETERIORATING
7STEPS
1. Initial cleaning
2. Counter measures for the causes of forced deterioration& improve hard to access
3. Preparation of tentative JH standards
4. General inspection
5. Autonomous Inspection
6. Standardization
7. Autonomous Management
25. 5. Pillars of TPM
3 PLANNED MAINTENANCE
THIS PILLAR AIMED TOWARDS
• TROUBLE FREE MACHINES AND EQUIPMENTS
• PRODUCING DEFECT FREE PRODUCTS FOR TOTAL CUSTOMER SATISFACTION
FOUR CATEGORIES
• PREVENTIVE MAINTENANCE
• BREAK DOWN MAINTENANCE
• CORRECTIVE MAINTENANCE
• MAINTENANCE PREVENTION
BENEFITS
• ACHIEVE AND SUSTAINAVAILABILITY OF MACHINES
• OPTIMUM MAINTENANCE COST
• REDUCES SPARES INVENTORY
• IMPROVE RELIABILITY AND MAINTENABILITY OF MACHINES
26. 5. Pillars of TPM
4 QUALITY MAINTENANCE
THIS PILLAR AIMED TOWARDS
• CUSTOMER DELIGHT THROUGH HIGHEST QAULITY
• DEFECT FREE MANUFACTURING
• ELIMINATING NON CONFORMANCES IN A SYSTMATIC MANNER
• REACTIVE TO PROACTIVE LIKE (QUALITY CONTROL TO QUALITY ASSURANCE)
BENEFITS
1. DEFECT FREE CONDITION AND CONTROL OF EQUIPMENTS
2. QM ACIVITY TO CONTROL QUALITY ASSURANCE
3. FOCUS OF PREVENTION OF DEFECTS AT SOURCE
4. FOCUS ON POKA-YOKE (FOOL PROOF SYSTEM)
5. IN LINE DETECTION AND SEGREGATION OF DEFECTS
6. EFFECTIVE IMPLEMENTATION OF OPERATOR QUALITY ASSURANCE
7. ACHIEVE & SUSTAIN CUSTOMER COMPLAINT ZERO
27. 5. Pillars of TPM
5 EDUCATION TRAINING
THIS PILLAR AIMED TOWARDS
• DEVELOPING MULTISKILL EMPLOYEES WHOSE MORALE IS HIGH AND WHO HAS
EAGER TO COME TO WORK AND PERFORM ALL REQUIRED FUNCTIONS
EFFECTIVELY AND INDEPENDENTLY
• EMPLOYEES WILL BE TRAINED TO ADDRESS THE PROBLEM BY FINDING THE
ROOT CAUSE & ELIMINATING THEM
• THE GOAL IS TO CREATE A FACTORY FULL OF EXPERTS
BENEFITS
1. ACHIEVE AND SUSTAIN ZERO LOSSES DUE TO LACK OF KNOWLEDGE /SKILLS
/TECHNIQUE
2. REMOVE FATIGUE AND MAKE WORK MORE ENJOYABLE
3. UPGRADING THE OPERATING & MAIN
28. 5. Pillars of TPM
6 DEVELOPMENT MANAGEMENT
THIS PILLAR AIMED TOWARDS
• Collection & utilization of feedback information regarding present products before
the start of the design
Measuring needs for “ Easy of manufacturing “ by analyzing the process for present products.
• Measuring needs for “ Easy of manufacturing” by analyzing process of new products in the
stage of planning & design of products.
By identifying failures possibilities based on design reviews of new products.
By identifying failures possibilities based on trail manufacturing & test of new products.
BENEFITS
1. REDUCES LEAD TIME TO NEW PRODUCT LAUNCH
2. REDUCE THE LOSSES
3. COST EFFECTIVE
29. 5. Pillars of TPM
7 SAFETY HEALTH ENVIROMENT
THIS PILLAR AIMED TOWARDS
• CREATE SAFE WORK PLACE AND SAFE WORK PRACTICE
• THIS PILLAR PLAY VITAL ROLE WITH OTHER PILLARS ON REGULAR BAISI
BENEFITS
• ZERO ACCIDENT
• ZERO FIRES
• ZERO HELATH DAMAGES
• SAFE WORKING CONDITION
• SAFE WORK PRACTICE
30. 5. Pillars of TPM
8 OFFICE TPM
THIS PILLAR AIMED TOWARDS
• TO IMPROVE PRODUCTIVITY
• EFFICIENCY IN THE ADMINSTRATIVE FUNCTIONS AND IDENTIFY TO ELEMINATE LOSSES
• ANALYZYING PROCESSES AND PROCEDURES TOWARDS INCREASED OFFICE AUTOMATION
BENEFITS
• INVENTORY REDUCTION
• LEAD TIME REDUCTION OF CRITICAL PROCESS
• EQUILISING THE WROK LOAD
• RETRIEVAL TIME REDUCTION (REDUCE REPETITIVE WORK)
• BETTER UTYILIZED WORK AREA
• REUDCTION IN ADMINISTRATIVE COSTS
31. Differences between TQM and TPM
Category TQM TPM
Object Quality ( Output and
effects )
Equipment ( Input and cause
)
Mains of attaining goal
Systematize the
management. It is software
oriented
Employees participation and
it is hardware oriented
Target Quality for PPM Elimination of losses and
wastes.
