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TOTAL PRODUCTIVE MAINTENANCE
PRESENTED BYKARAN PARMAR 1530/06,IEM-2 NIT KKR.
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DEFINITION Total Productive Maintenance
(TPM) is a maintenance program which involves a newly defined concept for maintaining plants and equipment. The 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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HISTORY:-
Evolved from TQM. Japanese concept. (1951) Nippondenso was the first company.(1960) The first widely attended TPM conference
held in the United States occurred in 1990.
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TYPES OF MAINTENANCE 1. Breakdown maintenance 2. Preventive maintenance 2a. Periodic maintenance ( Time based
maintenance - TBM) 2b. Predictive maintenance 3. Corrective maintenance 4. Maintenance prevention
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LIFETIME FAILURE RATES
improper usefailure
“normal” failure Wearoutfailure
Failurerate
Lifetime
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SHIFT IN ATTITUDES
Operator Maintenance
Conventional
I use I maintain &I fix
Operator Maintenance
NEW TPM
We maintain
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AUTONOMOUS MAINTENANCEThe principal way in which production workers
participate in TPM
Purpose
2. Helps operators learn more about their equipment.
4. Prepares operators to be active partners with maintenance and engineering in improving
equipment performance and reliability
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BENEFITS OF TPM FOR OPERATORS & MAINTENANCE
PERSONNEL
Increased skills through additional training Better job satisfaction
More challenging work More involvement in solving equipment problems Workers gets the feeling of owning of machine.
Better job security
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STEPS IN INTRODUCTION OF TPM IN AN ORGANIZATION
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VARIOUS STAGES :
a). PREPARATORY STAGE b). INTRODUCTION STAGEc). IMPLEMENTATIONd). INSTITUTIONALISING STAGE
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Organization Structure for TPM Implementation :
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Pillars of TPM
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PILLAR 1 - 5S :
Japanese TermEnglish Translation
Equivalent 'S' term
Seiri Organisation Sort
Seiton Tidiness Systematise
Seiso Cleaning Sweep
Seiketsu Standardisation Standardise
Shitsuke Discipline Self - Discipline
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PILLAR 2 - JISHU HOZEN ( AUTONOMOUS MAINTENANCE ) :
This pillar is geared towards developing operators to be able to take care of small maintenance tasks, thus freeing up the skilled maintenance people to spend time on more value added activity and technical repairs. The operators are responsible for upkeep of their equipment to prevent it from deteriorating.
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PILLAR 3 - KAIZEN :
"Kai" means change, and "Zen" means good.
This pillar aims at reducing losses in the workplace that affect our efficiencies.
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PILLAR 4 - PLANNED MAINTENANCE :
PILLAR 4 - PLANNED MAINTENANCE :It is aimed to have trouble free machine and
equipments producing defect free products for total customer satisfaction . Types :-
Breakdown Maintenance Preventive Maintenance Corrective Maintenance Maintenance Prevention
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PILLAR 5 - QUALITY MAINTENANCE :
QM activities is to set equipment conditions that preclude quality defects, based on the basic concept of maintaining perfect equipment to maintain perfect quality of products.
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PILLAR 6 - TRAINING :
Phase 1 : Do not know.Phase 2 : Know the theory but cannot do.Phase 3 : Can do but cannot teach(skilled)Phase 4 : Can do and also teach. (expert).
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THE PEOPLE OF SUCCESSFUL TPM
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PILLAR 7 - OFFICE TPM :
Office TPM must be followed to improve productivity, efficiency in the administrative functions and identify and eliminate losses. This includes analyzing processes and procedures towards increased office automation.
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PILLAR 8 - SAFETY, HEALTH AND ENVIRONMENT
Target : Zero accident, Zero health damage Zero fires.
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DIRECT BENEFITS OF TPM OEE up by 25-65%. Rectify customer complaints. Reduce the manufacturing cost by 30%. Satisfy the customers needs by 100 % . Reduce accidents. Follow pollution control measures.
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INDIRECT BENEFITS OF TPM Higher confidence level among the
employees. Keep the work place clean, neat and
attractive. Favorable change in the attitude of the
operators. Achieve goals by working as team. Share knowledge and experience. The workers get a feeling of owning the
machine.
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24
MAINTENANCE COSTS FULL COST VIEW
Maintenance Commitment
Cost
Optimal
Total costs
Full cost of breakdowns
Preventive maintenance costs
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CONCLUSION:
Today, with competition in industry at an all time high, TPM may be the only thing that stands between success and total failure for some companies.
If everyone involved in a TPM program does his or her part, an unusually high rate of return compared to resources invested may be expected.
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REFERENCES:
Wikipedia Journal of Industrial Engineering Industrial Engineering & Quality Maintenance www.scribid.co.in www.google.com
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THANK THANK YOU.YOU.
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QUERIES ?????