TOTAL PRODUCTIVE MAINTENANCE (TPM)

Presented by :Sanjay joshi 39143

Contents
Introduction to TPM TPM Philosophy TPM pillars TPM Goals Factors affecting equipment effectiveness Benefits of TPM. Todays Challenges. conclusion

Introduction
Manufacturing excellence approach of Toyota and other excellent Japanese companies since the 70s. Evolved due to continuing Energy Crisis and Globalization challenges to achieve More with Less. TPM is foundation for JIT, Poka Yoke, Lean Manufacturing & Zero Defects.

TPM Philosophy
Maximize overall equipment efficiency Zero Accidents, Zero Defects, Zero Breakdowns. Philosophy of Prevention. Proactive vs. Reactive. All management levels from senior managers to operators Focused Improvement.

What is TPM

Total Productive maintenance =

Preventive maintenance + Maintenance prevention + Maintainability Improvement It can be considered as the medical science of machines. A concept for maintaining plants and equipment. Increase production while, at the same time, increasing employee morale and job satisfaction.

TPM Is a Paradigm Shift

Old Attitude I operate, you fix I fix, you design I design, you operate

TPM Attitude We are all responsible for our equipment, our plant, and our future.

Why TPM

Reduce cost. Producing low cost goods without reducing product quality. Produce a low batch quantity at the earliest possible time. Avoid wastage in a quickly changing economic environment. Goods send to the customers must be non defective.

TPM pillars

PILLAR 1:- 5s
5s have the following meanings: SEIRI - Sort out . SEITON - stabilize . SEISO - Shine the workplace . SEIKETSU Standardization. SHITSUKE - sustain .

PILLAR 2 :- JISHU HOZEN ( Autonomous maintenance )

Makes operators to be able to take care of small maintenance tasks. Daily/Time-Based Maintenance Cleaning Lubrication Tightening Daily inspection by using 5 SENSES.

PILLAR 3:- KAIZEN

kaizen is for small improvements, but carried out on a continual basis . Involve all people in the organization. These activities are not limited to production areas and can be implemented in administrative areas as well.

PILLAR 4:-Planned Maintenance

This breaks maintenance down into 4 "families" or groups.

Preventive Maintenance . Breakdown Maintenance. Corrective Maintenance . Maintenance Prevention .

PILLAR 5:- Quality Maintenance

customer delight through highest quality through defect free manufacturing. Focus improvement. Transition is from reactive to proactive (Quality Control to Quality Assurance). Maintaining perfect equipment to maintain perfect quality of products.

PILLAR 6 TRAINING
It is aimed to: Have multi-skilled revitalized employees whose morale is high. Education is given to operators to upgrade their skill. The different phase of skills are Phase 1 : Do not know. Phase 2 : Know the theory but cannot do. Phase 3 : Can do but cannot teach Phase 4 : Can do and also teach.

PILLAR 7:-Office TPM

Office TPM is to improve productivity, efficiency in the administrative functions and identify and eliminate losses. Addresses following major losses. Processing loss . Communication channel breakdown, telephone and fax lines. Non availability of correct on line stock status . Customer complaints due to logistics. Expenses on emergency dispatches/purchases.

PILLAR 8 - SAFETY, HEALTH AND ENVIRONMENT

Focus is on to create a safe workplace and a surrounding area. Main aim of this pillar is : Zero accident. Zero health damage. Zero fires.

TPM Goals

Zero accidents. Zero rework. Zero unplanned downtime. Zero speed losses. Zero defects. Zero waste.

Factors affecting equipment effectiveness

Equipment failure (breakdown). Setup and adjustment downtime. Idling and minor stoppages. Reduced speed. Process defects. Reduced yield.

Six Major Losses

Down Time.
Breakdowns due to equipment failure. Setup and adjustment (e.g. exchange of dies in injection molding machines, etc.)

Speed Losses.
Idling and minor stoppages (abnormal operation of sensor, etc.). Reduced speed (discrepancies between designed and actual speed of equipment)

Defects.
Defects in process and rework (scrap and quality defects requiring repair) Reduced yield between machine startup and stable production.

Benefits of TPM
Direct benefits of TPM
Increase productivity. Rectify customer complaints. Reduce the manufacturing cost up to 30%. Satisfy the customers needs by 100 % ( Delivering the right quantity at the right time, in the required quality. ) Reduce accidents. Follow pollution control measures.

Indirect benefits of TPM

Higher confidence level among the employees. Keep the work place clean, neat and attractive. The workers get a feeling of owning the machine.

TVS Motor Company Ltd, Hosur

Data for year 2008-2009.

Source: TVS Motors India Ltd.

TPM award winning companies in 2007-08.

Bajaj Auto Ltd. Chakan Plant. Hindustan Unilever Ltd, Pune Tea Exports Factory. National Engineering Industries Ltd, Newai Plant. Sona Koyo Steering Systems Ltd, Gurgaon. Titan Time Products Limited . TVS Motor Company Hosur-Plant 2 J.K. Paper Ltd. Papaer Mills Jindal Stainless Ltd., Hisar. The Tata Iron & Steel Company Limited, Precision Tube Mill, Tubes Division

Todays Challenges.

The Quality Challenge. Just-In-Time. Cycle Time Reduction. Set Up Reduction. Cost Reduction. Capacity Expansion. Other Issues Environment Energy Conservation

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. 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. Employees must be educated and convinced that TPM is not just another "program of the month" and that management is totally committed to the program and the extended time frame necessary for full implementation. 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.