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Group :
Awais Ghaffar BSME 01093 – 068Owais Ahmed BSME 01093 – 033Hafiz M. Ahmed BSME 01093 –
041 Zeeshan
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TPM
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Overview:
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What is TPM ?Total Productive Maintenance (TPM) is a maintenance program which involves a newly defined concept for maintaining plants and equipment.
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History
TPM is a innovative Japanese concept. The origin of TPM can be traced back to 1951
when preventive maintenance was introduced in Japan.
The preventive maintenance concept was taken from the Americans.
Nippondenso was the first company to introduce plant wide preventive maintenance in 1960.
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Goal of TPMThe goal of the TPM program is to markedly increase production while, at the same time, increasing employee morale and job satisfaction.
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Why TPM ?
TPM was introduced to achieve the following objectives. Producing goods without reducing product
quality.Reduce cost.Increased Production Rate.Goods sent to the customers must be non
defective.
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Types of maintenance :
1. Breakdown Maintenance2. Preventive Maintenance
i. Periodicii. Predictive
3. Corrective Maintenance4. Maintenance Prevention
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1. Breakdown Maintenance :“It means that people waits until equipment
fails and repair it.”
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2. Preventive Maintenance :“It is a daily maintenance ( cleaning, inspection, oiling and re-tightening )”
a) Periodic Maintenance :Time based maintenance which is done periodically.
b) Predictive Maintenance :This is a method in which the service life of important part is predicted based on inspection.
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3. Corrective Maintenance :“Equipment with design weakness must be
redesigned to improve reliability or improving maintainability”
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4. Maintenance Prevention :“It indicates the design of a new equipment”
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Pillars of TPM
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PILLAR 1 - 5S :
Japanese TermEnglish
TranslationEquivalent 'S' term
Seiri Organization Sort
Seiton Tidiness Systematize
Seiso Cleaning Sweep
Seiketsu Standardization Standardize
Shitsuke Discipline Self - Discipline
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PILLAR 2 Autonomous maintenance
Policy :Uninterrupted operation of equipments.Flexible operators to operate and maintain
other equipments.Eliminating the defects at source through
active employee participation.
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PILLAR 3 - KAIZEN :"Kai" means change, and "Zen" means
good
Kaizen Target :Achieve and sustain zero loses with respect
to minor stops, measurement and adjustments, defects and unavoidable downtimes.
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PILLAR 4 PLANNED MAINTENANCE :“It is aimed to have trouble free machines
and equipments.”
This breaks maintenance down into 4 "families" or groups which was defined earlier.
Préventive Maintenance Breakdown Maintenance Corrective Maintenance Maintenance Prévention
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PILLAR 5 QUALITY MAINTENANCE :Target :Achieve and sustain customer complaints at
zeroReduce in-process defectsReduce cost of quality
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PILLAR 6 - TRAINING :
Policy :Focus on improvement of knowledge, skills
and techniques.Training to remove employee fatigue and
make work enjoyable.
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PILLAR 7 - OFFICE TPM :
Office TPM and its Benefits :Better utilized work areaReduced manpowerReduced inventory levels in all parts of the
supply chainClean and pleasant work environment.
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PILLAR 8 SAFETY, HEALTH & ENVIRONMENT Target :Zero accident.Zero health
damage.Zero fires.
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Applications In Pakistan
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Conclusion:Now a days TPM may be the only thing that
stands between success and total failure for some companies.
It has been proven to be a program that works.
It can be adapted to work not only in industrial plants, but in construction, building maintenance, transportation, and in a variety of other situations.
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References:http://www.plant-maintenance.com/articles/tpm_intro.shtmlhttp://www.densopartsweb.com/100/TPM100StudyGuide.pdfhttp://www.strategosinc.com/tpm_pillars_4.htm
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