TOTAL PRODUCTIVE MAINTENANCE Presentation by Swamynathan. S. M AP/ECE/SNSCT 3/16/2018 swamynathan. s. m/tqm/unit 4/TPM 1
TOTAL PRODUCTIVE MAINTENANCE …. GOAL 1. Increase production while, at the same time, increasing employee morale and job satisfaction. 2. Hold emergency & unscheduled maintenance to a minimum. Maintenance is no – longer regarded as a Non – Profit activity. 3/16/2018 swamynathan. s. m/tqm/unit 4/TPM 2
TOTAL PRODUCTIVE MAINTENANCE …. Why we need TPM ? The major objectives of the TPM are listed as under : 1. 2. 3. 4. Avoid wastage in quickly changing environment. Reduce Cost of Manufacturing. Produce a low batch quantity at the earliest possible time. Goods send to Customers must be “ non – defective” 3/16/2018 swamynathan. s. m/tqm/unit 4/TPM 3
TOTAL PRODUCTIVE MAINTENANCE …. TYPES OF MAINTENANCE Breakdown Maintenance 2. Preventive Maintenance a). Periodic Maintenance b). Predictive Maintenance 3. Corrective Maintenance 4. Maintenance Prevention 1. 3/16/2018 swamynathan. s. m/tqm/unit 4/TPM 4
TOTAL PRODUCTIVE MAINTENANCE …. TPM TARGETS 1. PRODUCTION I). Obtain Minimum 80% Overall Production Efficiency ii). Obtain Minimum 90% Overall Equipment Effectiveness iii). Run the Machine during lunchtime 2. 3. 4. 5. 6. QUALITY Operate in a manner, so that there are no customer complaint COST Reduce the manufacturing cost by ----- Per Cent DELIVERY Achieve 100% success in delivering the goods as required by the customer SAFETY Maintain an accident free environment MULTYTASK Develop multiskilled & flexible workers. 3/16/2018 swamynathan. s. m/tqm/unit 4/TPM 5
TOTAL PRODUCTIVE MAINTENANCE …. Motives of TPM a) b) c) Adoption of Life – Cycle approach for improving the overall performance of production equipments Improving Productivity by highly motivated workers which is achieved by Job – Enlargement Formation of team of volunteers for activities viz, cause of failure, possible reduction of cycle time; and equipment / process modifications. Uniqueness of TPM The major difference between TPM and other concepts is that the operators are also made to involve in the maintenance process. 3/16/2018 swamynathan. s. m/tqm/unit 4/TPM 6
TOTAL PRODUCTIVE MAINTENANCE …. Direct Benefits of TPM 1. 2. 3. 4. 5. 6. Increase Productivity and Overall Plant Efficiency by 1. 5 to 2 times Rectify customers complaints Reduce manufacturing cost by …. percent Satisfy the customers needs by 100% Reduce accidents Comply with all relevant governmental regulations 3/16/2018 Indirect Benefits of TPM 1. Higher confidence level 2. 3. 4. 5. 6. among the workers Keep the work place clean, neat and attractive Favourable change in the attitude of the operators Achieve goals by working as Team Share knowledge and experience The worker get a feeling of OWNING the machine swamynathan. s. m/tqm/unit 4/TPM 7
TOTAL PRODUCTIVE MAINTENANCE …. Introducing TPM at a Production Unit STEP – 1. Preparatory Stage n n n Announcement by TOP MANAGEMENT to all about TPM introduction in the organization Initial education and publicity for TPM Setting up TPM & Departmental committees Establishing the TPM working systems & target A master plan for institutionalizing STEP – 2. Introduction Stage STEP – 3. Implementation STEP – 4. Institutionalizing Stage 3/16/2018 swamynathan. s. m/tqm/unit 4/TPM 8
TOTAL PRODUCTIVE MAINTENANCE …. 5 S Autonomus Maintenance Planned Maintenance TOP MANAGEMENT TPM OFFICE TPM Responsible Plant Manager Individual Improvement Quality Maintenance 3/16/2018 Early Equipment Management Safety swamynathan. s. m/tqm/unit 4/TPM Training & Development 9
TOTAL PRODUCTIVE MAINTENANCE …. PILLARS OF TPM JISHU HOZEN KOBETSU KAIZEN Planned Maintenance Quality Maintenance Training Office TPM Safety , Health & Environment 5 S SEIRI SEITON SEISO 3/16/2018 SEIKETSU SHITSUKE swamynathan. s. m/tqm/unit 4/TPM 10
TOTAL PRODUCTIVE MAINTENANCE …. PILLARS OF TPM PILLAR 1 : 5 S TPM starts with 5 S. Problems can not be clearly seen when the workplace is unorganized. Cleaning and organizing the workplace helps the team to uncover problems. Making problems visible is the FIRST STEP of improvement. SEIRI SEITON SEISO SEIKETSU SHITSUKE 3/16/2018 – SORTOUT – ORGANIZE – SHINE THE WORKPLACE – STANDARDIZATION – SELF DISCIPLINE swamynathan. s. m/tqm/unit 4/TPM 11
TOTAL PRODUCTIVE MAINTENANCE …. PILLARS OF TPM PILLAR 2 : JISHU HOZEN (Autonomus Maintenance) This pillar is geared towards developing Operators to be able to take care of small maintenance tasks, thus freeing up skilled maintenance people to spend time on more value added activity and technical repairs. The operators are responsible for up keep of their equipment to prevent it from deteriorating. 3/16/2018 swamynathan. s. m/tqm/unit 4/TPM 12
TOTAL PRODUCTIVE MAINTENANCE …. PILLARS OF TPM PILLAR 2 : JISHU HOZEN…. POLICY 1. 2. 3. 4. Uninterrupted operation of equipments Flexible operators to operate & maintain other equipments Eliminating the defects at source through active employee participation Stepwise implementation of JISHU HOZEN activities. JH TARGETS 1. 2. 3. Reduce process time by ………% Reduce oil/ lubricants consumption by ………. . % Increase use of JH JH STEPS 1. 2. 3. 4. 5. 6. 7. 8. Preparation of employees Initial cleanup of machines Take counter measures Fix tentative JH standards General inspection Autonomus inspection Standardization Autonomus management 3/16/2018 swamynathan. s. m/tqm/unit 4/TPM 13
TOTAL PRODUCTIVE MAINTENANCE …. PILLARS OF TPM PILLAR 3 : KAIZEN KAI means change and ZEN means good (for the better). Basically Kaizen is for small improvements, but carried out on a continual basis and involves all people in the organization. The principal behind is that “ a very large number of small improvements are more effective in an organizational environment than a few improvements of large value. This pillar is aimed at reducing losses in the work place that affect our efficiencies. By using a detailed and through procedure, we eliminate losses in a systematic method using various Kaizen Tools. These activities are not restricted to production areas and can be implemented in administration area as well. 3/16/2018 swamynathan. s. m/tqm/unit 4/TPM 14
TOTAL PRODUCTIVE MAINTENANCE …. PILLARS OF TPM PILLAR 3 : KAIZEN…. POLICY – 1. Practice concepts of Zero Losses in every sphere of activities. 2. Relentless pursuit to achieve cost reduction targets in all sources. 3. Relentless pursuit to improve overall plant equipment effectiveness. 4. Extensive use of PM analysis as tool to eliminate losses. 5. Focus on easy handling of operators. TARGET – Achieve and sustain zero losses with respect to minor stops, measurement and adjustments, defects and unavoidable downtime. It also aims to achieve …. . % manufacturing cost reduction. 3/16/2018 swamynathan. s. m/tqm/unit 4/TPM 15
TOTAL PRODUCTIVE MAINTENANCE …. PILLARS OF TPM PILLAR 4 : PLANNED MAINTENANCE It is aimed to have trouble free machines and equipments producing defect free products for total customer satisfaction. With planned maintenance, we evolve an effort from a reactive to a proactive method and use trained maintenance staff to help train the operators to better maintain their equipment. Policy: n n 3/16/2018 Achieve and sustains availability of machines Optimum maintenance cost. Reduce spares inventory. Improve reliability and maintainability of machines. swamynathan. s. m/tqm/unit 4/TPM 16
TOTAL PRODUCTIVE MAINTENANCE …. PILLARS OF TPM PILLAR 4 : PLANNED MAINTENANCE…. TARGET: 1. Zero equipment failure and breakdown. 2. Improve reliability and maintainability by 50%. 3. Reduce maintenance cost by 20%. 4. Ensure availability of spares all the time. STEPS: n n n 3/16/2018 Equipment evaluation and recording present status. Restore deterioration and improve weakness. Building up information management system. Prepare time based information system, select equipment, parts and members and map on the plan. Prepare predictive maintenance system by introducing equipment diagnostic techniques and Evaluation of planned maintenance. swamynathan. s. m/tqm/unit 4/TPM 17
TOTAL PRODUCTIVE MAINTENANCE …. PILLARS OF TPM PILLAR 5 : QUALITY MAINTENANCE (QM) It is aimed towards customer delight through highest quality through defect free manufacturing. Focus is on eliminating non-conformances in a systematic manner. We gain understanding of what parts of the equipment affect product quality and begin to eliminate current quality concerns then move to potential quality concerns. Transition is from reactive to proactive. POLICY: n n n 3/16/2018 Defect free conditions and control of equipments QM activities to support quality assurances. Focus of prevention of defects at source Focus on fool proof (POKAYOKE) system. In-line detection and segregation of defects. Effective implementation of operator quality assurance. swamynathan. s. m/tqm/unit 4/TPM 18
TOTAL PRODUCTIVE MAINTENANCE …. PILLARS OF TPM PILLAR 5 : QUALITY MAINTENANCE (QM)… TARGET: Achieve and sustain customer complaints at zero. Reduce in-process defects by 50%. Reduce cost of quality by 50%. DATA REQUIREMENTS: Quality defects are classified as “CUSTOMER END DEFECTS” and IN HOUSE defects. For customer-end data, we have to get data on 1. Customer end line rejection 2. Field complaints In-house data include data related to products and data related to process. 3/16/2018 swamynathan. s. m/tqm/unit 4/TPM 19
TOTAL PRODUCTIVE MAINTENANCE …. PILLARS OF TPM PILLAR 6 : TRAINING It is aimed to have multi-skilled revitalized employees whose moral is high and who has eager to come to work and perform all required functions effectively and independently. Education is given to operators to upgrade their skill. The employees should be trained to achieve the form phase of skill which are as under: PHASE 1: Do not know. PHASE 2: Know theory but cannot do. PHASE 3: Can do but cannot teach. PHASE 4: Can do and also teach. 3/16/2018 swamynathan. s. m/tqm/unit 4/TPM 20
TOTAL PRODUCTIVE MAINTENANCE …. PILLARS OF TPM PILLAR 6 : TRAINING…. POLICY : 1. Focus on improvement of knowledge skill & techniques. 2. Creating a training environment for self learning based on felt needs. 3. Training curriculum/tools/assessment etc. Conductive to employees’ revitalization. 4. Training to remove employee fatigue and make work enjoyable. TARGET: 1. Achieve and sustain downtime due to want men at zero on critical machines. 2. Achieve and sustain zero losses due to lack of knowledge/skills/Techniques 3. Aim for 100% participation in suggestion scheme. 3/16/2018 swamynathan. s. m/tqm/unit 4/TPM 21
TOTAL PRODUCTIVE MAINTENANCE …. PILLARS OF TPM PILLAR 6 : TRAINING…. STEPS IN TRAINING ACTIVITES: 1. Setting policies and priorities and checking present status of education and training. 2. Establish of training system for operations and maintenance skill up gradation. 3. Training the employees for up gradation the operation and maintenance skills. 4. Preparation of training calendar. 5. Kick-off the training. 6. Evaluation of activities and study of future approach 3/16/2018 swamynathan. s. m/tqm/unit 4/TPM 22
TOTAL PRODUCTIVE MAINTENANCE …. PILLARS OF TPM PILLAR 7 : OFFICE TPM Office TPM should be started after activating from other pillars of TPM (JH, KK, and QM. PM). Office TPM must be flowed to improve productivity, efficiency in the administrative function and identify eliminate losses. This includes analyzing process and procedure towards increased office automation. Office TPM covers twelve major losses. These are: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Processing loss Cost loss including in areas such as procurement, accounts marketing leading to high inventories. Communication loss. Idle loss. Set-up loss. Accuracy loss Office equipment breakdown. Communication channel breakdown. Time spent on retrieval of information. Non availability of correct on line stock status. Customer complaints due to logistics. Expense on emergency dispatches/purchases. 3/16/2018 swamynathan. s. m/tqm/unit 4/TPM 23
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