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

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TPM-Total Productive Maintenance
Asif Iqbal Jan Mohd
Electrical & Automation engineer

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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

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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.

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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

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TPM-Total Productive Maintenance
EVALUATION OF TPM

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TPM-Total Productive Maintenance
What is TPM ?

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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.

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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

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TPM-Total Productive Maintenance

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TPM-Total Productive Maintenance

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TPM-Total Productive Maintenance

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Maintenance Approach
TPM-Total Productive Maintenance

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TPM-Total Productive Maintenance
5S

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TPM-Total Productive Maintenance

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TPM-Total Productive Maintenance

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TPM-Total Productive Maintenance

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TPM-Total Productive Maintenance
Identification of Major Losses

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TPM-Total Productive Maintenance

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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

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Thank you
Asif.jan@emiratessteel.com