TOTAL PRODUCTIVE MAINTENANCE (TPM)

NAME.MD DANISH KHAN(100106193) AMIR SUHAIL ADIL SHEIKH (100106198) (10010 )

BRANCH.MECHANICAL SECTION.(B) PRESENTATION ON.TOTAL PRODUCTIVE

MAINTENANCE

Definition of total productive maintenance (TPM)

TPM is a management process developed for improving productivity by making processes more reliable and less wasteful.TPM is an extension of TQM(Total Quality Management). The objective of TPM is to maintain the plant or equipment in good condition without interfering with the daily process. To achieve this objective, preventive and predictive maintenance is required. By following the philosophy of TPM we can minimize the unexpected failure of the equipment.

 Total productive maintenance(TPM) originated in Japan in 1971 as a method for improved machine availability through better utilization of maintenance and production resources.

TPM in three words:

Total = All individuals in the organization working together. Productive = production of goods that meet or exceed customers expectations. Maintenance = keeping equipment and plant in good condition at all times.

TPM is Planned, Predictive, & Preventive

1. Starts with 5S / Visual Factory 2. Builds a comprehensive Downtime Database by cause, frequency, and duration 3. Predicts and prevents downtime by PM system 4. Expands role of Operator as first point of early warning and prevention. 5. Develops Professional Maintenance skills
6.Builds a comprehensive downtime
7. Predicts and prevents downtime by PM system 8. Expands role of Operator as first point of early warning and prevention 9. Professional Maintenance data base by cause, frequency, and duration

Concept of (TPM)
Total Productive Maintenance (TPM) which is one of the key concepts of Lean Manufacturing, challenges the view that maintenance is no more than a function that operates in the background and only appears when needed. The objective of TPM is to engender a sense of joint responsibility between supervision, operators and maintenance workers, not simply to keep machines running smoothly, but also to extend and optimise their performance overall. The results are proving to be remarkable.

Reasons for (TPM)

Avoid wastage in quickly changing economic environment. Producing goods with out reducing product quality. Reduce cost for production Produce a low batch quantity at the earliest time. Goods send to the customer must be non defective.

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

 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.

Process of (TPM)
Maintenance has traditionally been viewed as a separate entity outside of the manufacturing process. As companies began to identify the role of maintenance in the production process a gradual shift in thinking occurred. TPM emerged out of the need to integrate maintenance with manufacturing to improve productivity and asset availability. The culmination of change from a reactive/corrective maintenance environment to one that is based on preventative maintenance through predictive maintenance is the process of TPM.

 TPM is used to drive waste out of the manufacturing process by reducing or eliminating production time lost to machine failures. The goal of any TPM program is to ensure that machinery and equipment is always available to manufacture products for the end customer. By minimizing rework, slow running equipment and downtime, maximum value is added at the minimum cost.

 Successful TPM is a group effort where the entire organization works together to maintain and improve the equipment. One of the first steps in implementing TPM is forming teams that are empowered to improve the process. Flattening the organizational structure enables teams to address issues when they have the greatest impact - when they occur. As employees join TPM teams, operators are trained to perform routine maintenance items and assume an ownership role. Employees empowered to affect the process will typically be in a position to identify and create process improvements that would have normally been overlooked by management. An on-going refactoring of the process provides a method to implement improvements.

 THNK YOU