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TOTAL PRODUCTIVEMAINTENANCE

Aman (02)

Indranil (07)Priyabrat (15)

Shreelekha (17)


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What is TPM ???

Company-wide system developed to maintain,monitor, and improve all capital assets of a

company.

For production it is a system that maximizes

equipment effectiveness and maintains product

flow.

It is about getting the most overall benefit from

your equipment over the life of the equipment.TPM is not an overnight success. Implementing

it throughout a plant correctly takes several

years.


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Origin of TPM

Introduced in 1971 as a method for improvingmachine availability through better utilization

of maintenance and production resources.

Proactive approach that essentially aims toidentify issues as soon as possible and plan to

prevent them before occurrence.

3 goals - Zero Product Defects, Zero

Equipment Unplanned Failures and Zero

Accidents.


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Total Productive Maintenance

Brought operators into the picture.

Teamwork between operators and maintenance.

Involvement & support throughout the company.


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Benefits of TPM in an organization

Improved plant productivity and capacity.

Lower operating costs.

Improved equipment lifespan.

Better ability to satisfy customers.

Increases long-term viability.


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Benefits of TPM to the operators

and the maintenance personnel

Increased skills through additional training.

Better job satisfaction.

Operators More involvement in solving annoying

equipment problems.

Maintenance More challenging work.

Better job security.


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Implementation of TPM

Step 1

Announcement of TPM

Step 2 Launch of formal education program.

Step 3 Create an organizational support structure.

Step 4

Establish basic TPM policies and quantifiablegoals.

Step 5 Outline the master plan.


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Step 6 TPM kick off.

Step 7

Improve effectiveness of each piece ofequipment.

Step 8

Develop an autonomous maintenanceschedule for the operators.

Step 9

Develop a preventive maintenance plan for

each equipment.

Step 10 Training to improve skills.


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Step 11

Develop an early equipment managementprogram.

Step 12 Continuous improvement.


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TPM targets

Obtain minimum 90% OEE. Run the machines even during lunch hours.

Operate in a manner, so that there are no

customer complaints. Reduce the manufacturing cost by 30%.

Achieve 100% success in delivering the goods as

required by the customer. Maintain a accident free environment.

Develop Multi-skilled and flexible workers.


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Typical results of TPM

Overall equipment effectiveness increased by25-65%.

Quality defects decreased by 25-50%.

Maintenance expenditures decreased 10-50%.

Percent planned vs. unplanned maintenance

increased by 10-60%.


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Pillars of TPM

Source: http://tpmclubindia.org/


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Effective TPM eliminates

Equipment breakdowns

Defects, scrap, and rework

Safety Issues Mini stoppages

Reduced speed


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Overall equipment effectiveness

OEE measurements are used as a guide to thepotential improvement that can be made to an

equipment.

Commonly used as a key performanceindicator (KPI) in conjunction with lean

manufacturing efforts to provide an indicator of

success.


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THANK YOU !!!


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