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Introduction toIntroduction toTotal Productive MaintenanceTotal Productive Maintenance

Sachbudi Abbas [email protected]
mailto:[email protected]:[email protected]


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Sachbudi Abbas Ras Page 2

What is TPM?

It can be considered as the medicalscience of machines .Total Productive Maintenance (TPMTPM ) is amaintenance program which involves anewly defined concept for maintaining

plants and equipment.TPM is a company-wide team-based effort to build quality intoequipment and to improve overall equipment effectiveness.


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Total All employees are involved.It aims to eliminate all accidents , defects and breakdowns .

Productive Actions are performed while production goes on .Troubles for production are minimized.

MaintenanceKeep in good condition .Repair , clean and lubricate .

What is TPM?


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The goal is to markedly increaseproduction while, at the same time,increasing employee morale and job

satisfaction .TPM brings maintenance into focus as

a necessary and vitally important part ofthe business.

What is TPM?


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Down time for maintenance is scheduledas a part of the manufacturing day and, income cases, as an integral part of the

manufacturing process.The goal is to hold emergency and

unscheduled maintenance to aminimumminimum .

What is TPM?


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TPM Principles

Increase Overall Equipment Effectiveness(OEE).Improve existing planned maintenance

system .The operator is the best condition monitor.

Provide training to upgrade operations andmaintenance skills.Involve everyone and utilize cross-functional

teamwork .


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TPM Achieve the Following Objectives Avoid wastage in a quickly changing economicenvironment.

Producing goods without reducing productquality .Reduce cost .

Produce a low batch quantity at the earliestpossible time.Goods send to the customers must be non

defective .

Why TPM?


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TQM and TPM

The TPM program closely resembles thepopular Total Quality Management(TQM) program.

Many of the tools such as employeeempowerment , benchmarking ,

documentation , etc. used in TQM areused to implement and optimize TPM .


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1.Total commitment to the program by upperlevel management is required in bothprograms.

2. Employees must be empowered to initiatecorrective action, and

3. A long range outlook must be accepted asTPM may take a year or more to implementand is an on-going process.

TQM and TPM(The Similarities)

Changes in employee mind-set toward their job responsibilities must take place as well!


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TQM and TPM(The Differences)

Category TQM TPM

Object Quality ( Output andeffects )Equipment ( Input andcause )

Mains of attaininggoal

Systematize themanagement. It issoftware oriented

Employeesparticipation and it ishardware oriented

Target Quality for ppmElimination of lossesand wastes.


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Types of Maintenance

1. Breakdown MaintenanceIt means that people waits until equipmentfails and repair it .

Such a thing could be used when theequipment failure does notdoes not significantlyaffect the operation or production orgenerate any significant loss other thatrepair cost.


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2. Preventive Maintenance (1951)It is a daily maintenance (cleaning ,inspection , oiling and re-tightening )

designed to retain the healthy condition ofequipment and prevent failure through

The prevention of deterioration ,Periodic inspection , or Equipment condition diagnosis

To measure deteriorationdeterioration .



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2a. Periodic MaintenanceTime based maintenance consists ofperiodically

InspectingServicing and cleaning equipment , andReplacing parts

to prevent sudden failure and processsudden failure and processproblems!problems!



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2b. Predictive MaintenanceThis is a method in which the service life ofimportant part is predicted based oninspection or diagnosis, in order to use theparts to the limit of their service life.This is condition based maintenance whichmanages trend values, by measuring andanalyzing data about deterioration and

employs a surveillance system.



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3. Corrective Maintenance (1957)It improves equipment and its componentsso that preventive maintenance can be

carried out reliably.Equipment with design weakness must beredesigned to improve reliability orimproving maintainability.



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4. Maintenance Prevention (1960)It indicates the design of a new equipment .Weakness of current machines aresufficiently studied (on site informationleading to failure prevention, easiermaintenance and prevents of defects, safetyand ease of manufacturing) and isincorporated before commissioning a new

equipment.



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The Evolution of TPM

TPM is a innovative Japanese concept .The origin of TPM can be tracked back to1951 when preventive maintenance wasintroduced in Japan.Nippondenso was the first company to

introduce plant wide preventivemaintenance in 1960.


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Nippondenso which already followedpreventive maintenance also addedautonomous maintenance done by

production operators.Preventive maintenance along withMaintenance prevention andMaintainability improvement gave birth toProductive MaintenanceProductive Maintenance (PM)(PM) .



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The aimaim of productive maintenance wasto maximize plant and equipmenteffectiveness to achieve optimum life

cycle cost of production equipment .Nippondenso had made quality circles ,

involving the employees participation.


Thus all employees took part inimplementing Productive maintenance!


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TPM Targets

P Obtain minimum 80% OPE .Obtain minimum 90% OEE .

Run the machines even during lunch (Lunchis for operators and not for machines!).

QOperate in a manner , so that there are nocustomer complaints.


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CReduce the manufacturing cost by 30% .

D

Achieve 100% success in delivering the goodsas required by the customer.

S

Maintain an accident free environment .M

Increase the suggestion by 3 times. Develop

multi-skilled and flexible workers .

TPM Targets


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Motives of TPM1. Adoption of life cycle approach for

improving the overall performance ofproduction equipment .

2. Improving productivity by highly motivatedworkers which is achieved by jobenlargement.

3. The use of voluntary small group activitiesfor identifying the cause of failure, possibleplant and equipment modifications.


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Uniqueness of TPM

The major difference between TPM andother concepts is that the operators arealso made to involve in the maintenance

process .The concept of I (production operators)Operate, You (Maintenance department)fix is not followed!


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TPM Objectives Achieve Zero Defects , Zero Breakdownand Zero Accidents in all functionalareas of the organization.

Involve people in all levels oforganization.

Form different teams to reduce defectsand Self Maintenance.


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Direct Benefits of TPM Increase productivity and OPE (Overall Plant

Efficiency ) by 1.5 or 2 times. Rectify customer complaints .

Reduce the manufacturing cost by 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 .


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Indirect Benefits of TPMHigher confidence level among theemployees.Keep the work place clean , neat andattractive .Favorable change in the attitude of the

operators . Achieve goals by working as team .


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Horizontal deployment of a new conceptin all areas of the organization.Share knowledge and experience.The workers get a feeling of owning themachine .

Indirect Benefits of TPM

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