What is TPM ?

Total Productive Maintenance (TPM) is

both
a philosophy to permeate throughout
an operating company touching
people of all levels
a collection of techniques and practices

Need 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
Reactive maintenance inherently wasteful and
ineffective with following disadvantages:

No warning of failure
Possible safety risk
Unscheduled downtime of
machinery
Production loss or delay
Possible secondary damage

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 plants
product increases

Costs include:

aimed at maximizing the

effectiveness (best possible return)
of business facilities and processes

It is a Japanese approach for

Stand-by machinery
A stand-by maintenance
team
A stock of spare parts

Lower inventory
Reduce accidents
2. Visibly transform the workplace
(plant environment)

Post production
Disrupted schedule
Repair cost
Stand-by machinery
Spare parts

TPM enables or provides:

The traditional maintenance
practices to change from
reactive to pro-active
A number of mechanisms whereby
Breakdowns are
analyzed
Causes
investigated
Actions taken to
prevent further
breakdowns
Preventive maintenance schedule to be made
more meaningful

3.

Raises the level of workers knowledge

and skills

As TPM activities begin to yield

above concrete results, it helps:

Why is TPM so popular and important ?

Three main reasons:

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

The workers to become

motivated
Involvement increases
Improvement
suggestions proliferate
People begin to think of
TPM as part of the job

1.

TPM Policy and Objectives

Policy and objectives:

To maximize overall equipment

effectiveness (Zero breakdowns and
failures, Zero accident, and Zero
defects etc) through total employee
involvement

1. Formally announce the decision

to introduce TPM
2. Conduct TPM introductory
education and publicity
campaign

To improve equipment reliability and

maintainability as contributors to
quality and to raise productivity

3. Create TPM promotion

organization

To aim for maximum economy in

equipment for its entire life

4. Establish basic TPM policy and

goals

To cultivate equipment-related
expertise and skills among operators

5. Draft a master plan for

implementing TPM

To create a vigorous and enthusiastic

work environment

Introduction
6.

Kick off TPM initiatives

(to cultivate the atmosphere to raise
morale, inspiration and dedication)
Implementation

TPM Corporate policy for the following

purposes:

7.

Build a corporate constitution designed to

maximize the effectiveness of facilities
i.
Conduct focused improvement
activities

To aim for world-class

maintenance, manufacturing
performance and quality

ii.

To plan for corporate growth

through business leadership

Establish and deploy autonomous

maintenance program

iii.

To promote greater efficiency through

greater flexibility

Implement planned maintenance

program

iv.

Conduct operation and

maintenance skills training

Revitalize the workshop and make the

most of employee talents

12 TPM Development Program Steps

8.

Build an early management system for new

products and equipment
Implementation (Contd.)
9.

Build a quality maintenance system

10. Build an effective administration and support

system
11. Develop a system for managing health, safety,
and the environment
Consolidation
12. Sustain a full TPM implementation and raise
levels (Prize)
Five fundamental TPM activities
1. Autonomous maintenance
2. Equipment improvement
3. Quality maintenance
4. MP(Maintenance Prevention) systembuilding
5. Education and training
TPM resembles TQM in following aspects:
1. Total commitment to the program
by upper level management
2. Employee empowered to initiate
corrective actions
3. Changes in employee mind-set
towards their job responsibilities

Tribology is defined as the science of

interacting surfaces in relative motion. The
word tribology comes from the Greek tribos,
meaning rubbing. In any machine there are
lots of component parts that operate by
rubbing together. Some examples are
bearings, gears, cams and tappets, tyres,
brakes, and piston rings.
One of the important objectives in tribology is
the regulation of the magnitude of frictional
forces according to whether we require a
minimum (as in machinery) or a maximum
(as in the case of anti-skid surfaces) . It must
be emphasized, however, that this objective
can be realized only after a fundamental
understanding of the frictional process is
obtained for all conditions of temperature,
sliding velocity, lubrication, surface finish,
and material properties.
Attractive Forces Between Material Bodies.
A distinction is usually made between an
adhesive force, which acts to hold two
separate bodies together (or to stick one
body to another) and a cohesive force, which
acts to hold together the like or unlike atoms,
ions, or molecules of a single body. However,
both forces result from the same basic
properties of matter. A number of phenomena
can be explained in terms of adhesion and
cohesion. For example, surface tension in
liquids results from cohesion, and capillarity
results from a combination of adhesion and
cohesion. The hardness of a diamond is due
to the strong cohesive forces between the
carbon atoms of which it is made. Friction
between two solid bodies depends in part
upon adhesion.

Viscosity resistance to gradual deformation

by shear stress
When fluid flows in a tube, the velocity near
by the axis faster than near By its wallshear
stress at different velocity.
If fluid that has no resistance to shear stress
ideal fluid or inviscid fluid
If viscosity very high for instance pitch
appear to be solid.
If fluid whose viscosity less than water
mobile liquid
If fluid whose viscosity higher than water
viscous liquid
Shear thinning : viscosity increase with the
rate of shear strain
Shear thickenning : visc.decrease with the
rate of shear strain
Thixotropic liquids : become less visc. Over
time when shaken, agitated or other stressed.
Rheopectic liquids : become more visc. When
shaken or agitated
Glass and polymer have very high visc .
( greater than 10 Pa. )
Fluidity is the reciprocal term of viscosity
symbol = 1/

WEAR is a process of removal of material

from one or both of two solid surfaces in solid
state contact, occurring when these two solid
surfaces are in sliding or rolling motion
together.
Bhushan and Gupta (1991)
Wear is the progressive damage, involving
material loss, which occurs on the surface of
a component as result of its motion relative

to
the
adjacent
John Williams

working

parts.

Occurrence of Wear depends on

Geometry of the surface
Applied load
The rolling and sliding velocities
Environmental conditions
Mechanical, Thermal, Chemical and
Metallurgical properties
Physical,
Thermal
and
Chemical
properties of the lubricant

Types of abrasive wear

Gouging abrasion
Large particles
High compression loads
High stress or grinding abrasion
Smaller particles
High compression load
Low stress or scratching abrasion
No compression load
Scratching abrasion while material is sliding
Polishing abrasion

Frictional wear / adhesive wear

Two bodies sliding over or pressed into each
other which promote the material
transfer from one to another.
Surface fatigue
Two surfaces contacting to each other under
pure rolling, or rolling with a small amount
of
sliding in contact
Contact fatigue
As one element rolls many times
over the other element

Maximum shear stress is higher

than fatigue limit

Environmental conditions produce a reaction

product on one or both of rubbing
surface and this chemical product is
subsequently removed by the rubbing action.
Methods for control of the wear
Lubrication technology
Materials substitution
Load reduction
Removal of impact conditions

Chemical wear