Tpm basic
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This document provides an overview of Total Productive Maintenance (TPM). It begins with definitions of TPM, noting that it aims for overall equipment effectiveness through the participation of all employees. The history of TPM is then summarized, originating from Japan in the 1950s. The objectives and principles of TPM are then outlined in brief, including using Overall Equipment Effectiveness as a metric and improving maintenance systems. Finally, the five pillars of TPM are listed as individual improvement, autonomous maintenance, planned maintenance, quality maintenance, and education and training.
Tpm basic
- 2. CONTENTS 1- What is TPM. 2- History of TPM. 3- Objective of TPM. 4- Principles of TPM. 5- Pillar of TPM.
- 3. CONTENTS 1- What Is TPM
- 4. 1. What Is TPM • TPM is a productive maintenance implemented by all employees in an organization. • TPM involves everyone in the organization from operators to senior management in equipment improvement.
- 5. 1. What Is TPM TPM in three words: T Total • Overall efficiency. • Total production system. • Participation of all employees. P Productive • Zero defect. • No trouble in operation. • Safety. M Maintenance • Longer life cycle of production system.
- 6. CONTENTS 2- History of TPM
- 7. 2. History of TPM • This is an innovative Japanese concept. • Developed in 1951. • Nippondenso was the 1st company that implemented TPM in 1960. • Based on these developments Nippondenso was awarded the distinguished plant prize for developing and implementing TPM, by the Japanese Institute of Plant Engineers ( JIPE ). • This Nippondenso became the first company to obtain the TPM certifications.
- 8. CONTENTS 3- Objective of TPM
- 9. 3. Objective of TPM • Increase production quality. • Increase job satisfaction. • Using teams for continuous improvement. • Improve the state of maintenance • Empower employees
- 10. CONTENTS 4- Principles of TPM
- 11. 3. Principles of TPM • A Use Overall Equipment Effectiveness (OEE) as a compass for success. • Improve existing planned maintenance systems • Work toward zero losses • Providing training to upgrade operations and maintenance skills • Involve everyone and utilize cross-functional teamwork
- 12. 3. Principles of TPM What is OEE Overall Equipment Efficiency OEE = A x P x Q A= Availability P= Performance Q= Quality
- 13. 3. Principles of TPM How To Calculate OEE Availability = Standard time Standard time – downtime Performance = Components Produced Components supposed to be Produced Quality = Total Acceptable Components Total Components produced
- 14. 3. Principles of TPM • Improve existing planned maintenance systems Types of maintenance Breakdown maintenance Preventive maintenance .periodic maintenance( time based maintenance) .Predictive maintenance Corrective maintenance
- 15. 3. Principles of TPM Breakdown maintenance • Repairs or replacements performed after a machine has failed to return to its functional state following a malfunction or shutdown. • e.g., an electric motor of a machine tool will not start, a belt is broken, etc. • Under such conditions, production department calls on the maintenance department to rectify the defect. • After removing the fault, maintenance engineers do not attend the equipment again until another failure or breakdown occurs.
- 16. 3. Principles of TPM Preventive maintenance • The primary goal of preventive maintenance is to prevent the failure of equipment before it actually occurs. • It is designed to preserve and enhance equipment reliability by replacing worn components before they actually fail. • It is a daily maintenance which includes cleaning, inspection, oiling and re-tightening of equipments.
- 17. 3. Principles of TPM Periodic maintenance (TBM) • Time based maintenance consists of periodically inspecting, servicing and cleaning equipment and replacing parts to prevent sudden failure and process problems. Benefits: • Extended life and use of the equipment. • Reliable production at the times when machine is needed most.
- 18. 3. Principles of TPM Predictive maintenance • This is a method in which the service life of important part is expected based on inspection or diagnosis, in order to use the parts to the limit of their service life. • Compared to periodic maintenance, predictive maintenance is condition based maintenance.
- 19. 3. Principles of TPM Predictive maintenance Benefits: • Increased plant readiness due to greater reliability of the equipment. • Many industries report from two to ten percent productivity increases due to predictive maintenance practices. • Reduced expenditures for spare parts and labor. • Reduces the probability of a machine experiencing a disastrous failure, and this results in an improvement in worker safety.
- 20. 3. Principles of TPM • Work toward zero losses Type of Losses 1. T- Transportation 2. I- Inventory 3. M-Motion 4. W- Waiting 5. O- Over Process 6. O-Over Production 7. D-Delay
- 21. CONTENTS 5- Pillars of TPM
- 22. 5. Pillars of TPM
- 23. 5. Pillars of TPM 1 INDIVIDUAL IMPROVEMENT
- 24. 5. Pillars of TPM 2 JISHU HOZEN (AUTONOMOUS MAINTENANCE) •THIS PILLAR DEVELOPS OPERATOR TO TAKE CARE OF SMALL MAINTENANCE TASKS . •RESULTING SKILLED MAINTENACE TEAM TO CONCETRATE ON VALUE ADDED AND TECHNICAL REPAIRS . •THE OPERATOR RESPONSIBLE FOR UP KEEP OFF THEIR EQUIPMENT TO PREVENT IT FROM DETERIORATING 7STEPS 1. Initial cleaning 2. Counter measures for the causes of forced deterioration& improve hard to access 3. Preparation of tentative JH standards 4. General inspection 5. Autonomous Inspection 6. Standardization 7. Autonomous Management
- 25. 5. Pillars of TPM 3 PLANNED MAINTENANCE THIS PILLAR AIMED TOWARDS • TROUBLE FREE MACHINES AND EQUIPMENTS • PRODUCING DEFECT FREE PRODUCTS FOR TOTAL CUSTOMER SATISFACTION THREE CATEGORIES • PREVENTIVE MAINTENANCE • BREAK DOWN MAINTENANCE • CORRECTIVE MAINTENANCE • BENEFITS • ACHIEVE AND SUSTAINAVAILABILITY OF MACHINES • OPTIMUM MAINTENANCE COST • REDUCES SPARES INVENTORY • IMPROVE RELIABILITY AND MAINTENABILITY OF MACHINES
- 26. 5. Pillars of TPM 4 QUALITY MAINTENANCE THIS PILLAR AIMED TOWARDS • CUSTOMER DELIGHT THROUGH HIGHEST QAULITY • DEFECT FREE MANUFACTURING • ELIMINATING NON CONFORMANCES IN A SYSTMATIC MANNER • REACTIVE TO PROACTIVE LIKE (QUALITY CONTROL TO QUALITY ASSURANCE) BENEFITS 1. DEFECT FREE CONDITION AND CONTROL OF EQUIPMENTS 2. QM ACIVITY TO CONTROL QUALITY ASSURANCE 3. FOCUS OF PREVENTION OF DEFECTS AT SOURCE 4. FOCUS ON POKA-YOKE (FOOL PROOF SYSTEM) 5. IN LINE DETECTION AND SEGREGATION OF DEFECTS 6. EFFECTIVE IMPLEMENTATION OF OPERATOR QUALITY ASSURANCE 7. ACHIEVE & SUSTAIN CUSTOMER COMPLAINT ZERO
- 27. 5. Pillars of TPM 5 EDUCATION TRAINING THIS PILLAR AIMED TOWARDS • DEVELOPING MULTISKILL EMPLOYEES WHOSE MORALE IS HIGH AND WHO HAS EAGER TO COME TO WORK AND PERFORM ALL REQUIRED FUNCTIONS EFFECTIVELY AND INDEPENDENTLY • EMPLOYEES WILL BE TRAINED TO ADDRESS THE PROBLEM BY FINDING THE ROOT CAUSE & ELIMINATING THEM • THE GOAL IS TO CREATE A FACTORY FULL OF EXPERTS BENEFITS 1. ACHIEVE AND SUSTAIN ZERO LOSSES DUE TO LACK OF KNOWLEDGE /SKILLS /TECHNIQUE 2. REMOVE FATIGUE AND MAKE WORK MORE ENJOYABLE 3. UPGRADING THE OPERATING & MAIN
- 28. 5. Pillars of TPM 6 DEVELOPMENT MANAGEMENT THIS PILLAR AIMED TOWARDS • Collection & utilization of feedback information regarding present products before the start of the design Measuring needs for “ Easy of manufacturing “ by analyzing the process for present products. • Measuring needs for “ Easy of manufacturing” by analyzing process of new products in the stage of planning & design of products. By identifying failures possibilities based on design reviews of new products. By identifying failures possibilities based on trail manufacturing & test of new products. BENEFITS 1. REDUCES LEAD TIME TO NEW PRODUCT LAUNCH 2. REDUCE THE LOSSES 3. COST EFFECTIVE
- 29. 5. Pillars of TPM 7 SAFETY HEALTH ENVIROMENT THIS PILLAR AIMED TOWARDS • CREATE SAFE WORK PLACE AND SAFE WORK PRACTICE • THIS PILLAR PLAY VITAL ROLE WITH OTHER PILLARS ON REGULAR BASIC BENEFITS • ZERO ACCIDENT • ZERO FIRES • ZERO HELATH DAMAGES • SAFE WORKING CONDITION • SAFE WORK PRACTICE
- 30. 5. Pillars of TPM 8 OFFICE TPM THIS PILLAR AIMED TOWARDS • TO IMPROVE PRODUCTIVITY • EFFICIENCY IN THE ADMINSTRATIVE FUNCTIONS AND IDENTIFY TO ELEMINATE LOSSES • ANALYZYING PROCESSES AND PROCEDURES TOWARDS INCREASED OFFICE AUTOMATION BENEFITS • INVENTORY REDUCTION • LEAD TIME REDUCTION OF CRITICAL PROCESS • EQUILISING THE WROK LOAD • RETRIEVAL TIME REDUCTION (REDUCE REPETITIVE WORK) • BETTER UTYILIZED WORK AREA • REUDCTION IN ADMINISTRATIVE COSTS
- 31. Differences between TQM and TPM Category TQM TPM Object Quality ( Output and effects ) Equipment ( Input and cause ) Mains of attaining goal Systematize the management. It is software oriented Employees participation and it is hardware oriented Target Quality for PPM Elimination of losses and wastes.