MAINTENANCE &TPM

Gopalakrishnan - Role Of Maintenance

 WHY MAINTENANCE?
• If left unattended, everything will
deteriorate – so, maintain
• Make the equipments available for
production at all times
• Prevent the equipment from Forced
deterioration
• Maintain the condition of the equipment
• Improve the performance & reliability of
the equipment

Gopalakrishnan - Role Of Maintenance

 What is FORCED DETERIORATION?

Natural Deterioration
Equipment Condition

Forced Deterioration

Time 
Gopalakrishnan - Role Of Maintenance
 ROLE OF MAINTENANCE
AIM:
• Zero Breakdowns
• Improve the Quality of maintenance
activities

APPROACH:
• Trap Defects
• Progressively eliminate the root causes

Gopalakrishnan - Role Of Maintenance

 PROGRESS MEASURES

• MTBF: Mean time Between Failures

• MTTR: Mean Time to Repair / Rectify

Problems Understood Counter measures applied Successful countermeasures

---------------------------------- x --------------------------------- x ---------------------------------------
Problems Known Problems understood Counter measures applied

Gopalakrishnan - Role Of Maintenance

 Classification & Allocation of Maintenance Activities
ACTIVITIES ALLOCATION
TARGET METHOD
Prevent / Measure / Restore Operators / Engineers

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Gopalakrishnan - Role Of Maintenance
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 TOTAL PRODUCTIVE MAINTENANCE

• PRODUCTION
• QUALITY
• COST
• DEVELOPMENT
• SAFETY
• MORALE

Gopalakrishnan - Role Of Maintenance

 POLICY
Our TPM Policy is to achieve
• Higher Overall Equipment Efficiency
• With reduced losses and
• High reliability of our process.

We commit to achieve this policy through

• “Zero Breakdowns ”,
• “Zero Defects” and
• “Zero Accidents”.

To achieve this, continuous skill up gradation of employees

will be done.

Gopalakrishnan - Role Of Maintenance

 PRINCIPLES
• Increase OEE

• Improve existing Planned Maintenance systems

• Routine Asset Care as a part of the job

• Increase Skills TRAIN OTHERS

KNOW

USE UNDERSTAND
• Maintenance Prevention

Gopalakrishnan - Role Of Maintenance

 PILLARS
• FOCUSSED (SELF) IMPROVEMENT
• AUTONOMOUS MAINTENANCE
• PLANNED MAINTENANCE
• QUALITY MAINTENANCE
• EDUCATION & TRAINING
• DEVELOPMENT MANAGEMENT
• SAFETY HEALTH ENVIRONMENT
• OFFICE TPM

Gopalakrishnan - Role Of Maintenance

 GOAL OF TPM
GOAL:
• Increase OEE
• Develop optimal relationship between equipment and
people

METHOD:
• Eliminate Six Losses

THROUGH:
• Measurement Cycle
• Condition Cycle
• Prevention Cycle

Gopalakrishnan - Role Of Maintenance

 OVERALL EQUIPMENT EFFECTIVENESS

OEE is a product of
Availability Rate x Speed Rate x Quality Rate

AR = No. of hours m/c run / No. of hours available

SR = No. of pcs produced / Standard production

QR = No. of pcs Accepted / No. of pcs produced

Gopalakrishnan - Role Of Maintenance

 SIX BIG LOSSES
1. BREAKDOWN LOSSES
2. SET-UP & ADJUSTMENT LOSSES
3. IDLING & MINOR STOP LOSSES
4. REDUCED SPEED OPERATION
5. SCRAP & RE-WORK LOSSES
6. START-UP LOSSES

• 7th loss is Blade-loss

Gopalakrishnan - Role Of Maintenance

 MEASUREMENT CYCLE
• COLLECT HISTORY FILE

• IDENTIFY THE ORIGINAL SPECIFICATIONS

OF THE EQUIPMENT SUPPLIED BY THE
MANUFACTURER

• COLLECT PERFORMANCE DATA OF THE

EQUIPMENT vis-à-vis SPECIFICATIONS

• DEFINE REVIEW PERIOD BASED ON THE

DATA COLLECTED

Gopalakrishnan - Role Of Maintenance

 CONDITION CYCLE
• CRITICALITY ASSESMENT OF THE
EQUIPMENT

• CONDITION APPRAISAL FOR THE

EQUIPMENT

• PLAN REFURBISHING

• PREPARE FUTURE CHECK-LIST BASED ON

THE OBSERVATIONS

Gopalakrishnan - Role Of Maintenance

 PROBLEM PREVENTION
• STANDARDIZATION OF ACTIVITIES

• P-M ANALYSIS (PHENOMENON –

MECHANISM ANALYSIS)

• SIMPLY, DO
AUTONOMOUS MAINTENANCE

Gopalakrishnan - Role Of Maintenance

 TPM …
• Gives us special lens to see things
• Drives us to do more focus on process
• Enables us to have control over the
equipment’s downtime
• Allows us to challenge Status Quo
• Forces us to Improve
• Helps us to Work Smarter

Gopalakrishnan - Role Of Maintenance