An Introduction to Total Productive

Maintenance (TPM)

By Venkatesh J

What is Total Productive Maintenance ( TPM ) ?

It can be considered as the medical science of machines. Total Productive Maintenance (TPM) is a
maintenance program which involves a newly defined concept for maintaining plants and equipment. The
goal of the TPM program is to markedly increase production while, at the same time, increasing employee
morale and job satisfaction.

TPM brings maintenance into focus as a necessary and vitally important part of the business. It is no
longer regarded as a non-profit activity. Down time for maintenance is scheduled as a part of the
manufacturing day and, in some cases, as an integral part of the manufacturing process. The goal is to
hold emergency and unscheduled maintenance to a minimum.

Why TPM ?

TPM was introduced to achieve the following objectives. The important ones are listed below.

Avoid wastage in a quickly changing economic environment.

Producing goods without reducing product quality.
Reduce cost.
Produce a low batch quantity at the earliest possible time.
Goods send to the customers must be non defective.

Similarities and differences between TQM and TPM :

The TPM program closely resembles the popular Total Quality Management (TQM) program. Many of the
tools such as employee empowerment, benchmarking, documentation, etc. used in TQM are used to
implement and optimize TPM.Following are the similarities between the two.

1. Total commitment to the program by upper level management is required in both programmes
2. Employees must be empowered to initiate corrective action, and
3. A long range outlook must be accepted as TPM may take a year or more to implement and is an on-going
process. Changes in employee mind-set toward their job responsibilities must take place as well.

The differences between TQM and TPM is summarized below.

Category TQM TPM

Object Quality ( Output and effects ) Equipment ( Input and cause )

Systematize the management. It is Employees participation and it is

Mains of attaining goal
software oriented hardware oriented

Target Quality for PPM Elimination of losses and wastes.

Types of maintenance :
1. Breakdown maintenance :

It means that people waits until equipment fails and repair it. Such a thing could be used when the
equipment failure does not significantly affect the operation or production or generate any significant loss
other than repair cost.

2. Preventive maintenance ( 1951 ):

It is a daily maintenance ( cleaning, inspection, oiling and re-tightening ), design to retain the healthy
condition of equipment and prevent failure through the prevention of deterioration, periodic inspection or
equipment condition diagnosis, to measure deterioration. It is further divided into periodic maintenance
and predictive maintenance. Just like human life is extended by preventive medicine, the equipment
service life can be prolonged by doing preventive maintenance.

2a. Periodic maintenance ( Time based maintenance - TBM) :

Time based maintenance consists of periodically inspecting, servicing and cleaning equipment and
replacing parts to prevent sudden failure and process problems.

2b. Predictive maintenance :

This is a method in which the service life of important part is predicted 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. It manages trend values, by measuring and analyzing data
about deterioration and employs a surveillance system, designed to monitor conditions through an on-line
system.

3. Corrective maintenance ( 1957 ) :

It improves equipment and its components so that preventive maintenance can be carried out reliably.
Equipment with design weakness must be redesigned to improve reliability or improving maintainability
4. Maintenance prevention ( 1960 ):

It indicates the design of a new equipment. Weakness of current machines are sufficiently studied ( on
site information leading to failure prevention, easier maintenance and prevents of defects, safety and
ease of manufacturing ) and are incorporated before commissioning a new equipment.

TPM - History:

TPM is a innovative Japanese concept. The origin of TPM can be traced back to 1951 when preventive
maintenance was introduced in Japan. However the concept of preventive maintenance was taken from
USA. Nippondenso was the first company to introduce plant wide preventive maintenance in 1960.
Preventive maintenance is the concept wherein, operators produced goods using machines and the
maintenance group was dedicated with work of maintaining those machines, however with the automation
of Nippondenso, maintenance became a problem as more maintenance personnel were required. So the
management decided that the routine maintenance of equipment would be carried out by the operators. (
This is Autonomous maintenance, one of the features of TPM ). Maintenance group took up only
essential maintenance works.

Thus Nippondenso which already followed preventive maintenance also added Autonomous maintenance
done by production operators. The maintenance crew went in the equipment modification for improving
reliability. The modifications were made or incorporated in new equipment. This lead to maintenance
prevention. Thus preventive maintenance along with Maintenance prevention and Maintainability
Improvement gave birth to Productive maintenance. The aim of productive maintenance was to
maximize plant and equipment effectiveness to achieve optimum life cycle cost of production equipment.

By then Nippon Denso had made quality circles, involving the employees participation. Thus all
employees took part in implementing Productive maintenance. Based on these developments
Nippondenso was awarded the distinguished plant prize for developing and implementing TPM, by
the Japanese Institute of Plant Engineers ( JIPE ). Thus Nippondenso of the Toyota group became the
first company to obtain the TPM certification.

TPM Targets:

P
Obtain Minimum 80% OPE.
Obtain Minimum 90% OEE ( Overall Equipment Effectiveness )
Run the machines even during lunch. ( Lunch is for operators and not for machines ! )

Q
Operate in a manner, so that there are no customer complaints.

C
Reduce the manufacturing cost by 30%.
D
Achieve 100% success in delivering the goods as required by the customer.

S
Maintain a accident free environment.

M
Increase the suggestions by 3 times. Develop Multi-skilled and flexible workers.
Motives of TPM 1. Adoption of life cycle approach for improving the overall performance of
production equipment.
2. Improving productivity by highly motivated workers which is achieved by job
enlargement.
3. The use of voluntary small group activities for identifying the cause of failure,
possible plant and equipment 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. The concept of "I ( Production
operators ) Operate, You ( Maintenance department ) fix" is not followed.

TPM Objectives 1. Achieve Zero Defects, Zero Breakdown and Zero accidents in all functional
areas of the organization.
2. Involve people in all levels of organization.
3. Form different teams to reduce defects and Self Maintenance.

Direct benefits of TPM 1. Increase productivity and OPE ( Overall Plant Efficiency ) by 1.5 or 2 times.
2. Rectify customer complaints.
3. Reducethe manufacturing cost by 30%.
4. Satisfy the customers needs by 100 % ( Delivering the right quantity at the right
time, in the required quality. )
5. Reduce accidents.
6. Follow pollution control measures.

Indirect benefits of TPM 1. Higher confidence level among the employees.

2. Keep the work place clean, neat and attractive.
3. Favorablechange in the attitude of the operators.
4. Achieve goals by working as team.
5. Horizontaldeployment of a new concept in all areas of the organization.
6. Share knowledge and experience.
7. The workers get a feeling of owning the machine.

OEE ( Overall Equipment Efficiency ) :

OEE = A x PE x Q

A - Availability of the machine. Availability is proportion of time machine is actually available out of time it
should be available.

A = ( MTBF - MTTR ) / MTBF.

MTBF - Mean Time Between Failures = ( Total Running Time ) / Number of Failures.
MTTR - Mean Time To Repair.

PE - Performance Efficiency. It is given by RE X SE.

Rate efficiency (RE) : Actual average cycle time is slower than design cycle time because of jams, etc.
Output is reduced because of jams
Speed efficiency (SE) : Actual cycle time is slower than design cycle time machine output is reduced
because it is running at reduced speed.

Q - Refers to quality rate. Which is percentage of good parts out of total produced sometimes called
"yield".

Steps in introduction of TPM in a organization :

Step A - PREPARATORY STAGE :

STEP 1 - Announcement by Management to all about TPM introduction in the organization :

Proper understanding, commitment and active involvement of the top management in needed for this
step. Senior management should have awareness programmes, after which announcement is made to
all. Publish it in the house magazine and put it in the notice board. Send a letter to all concerned
individuals if required.

STEP 2 - Initial education and propaganda for TPM :

Training is to be done based on the need. Some need intensive training and some just an awareness.
Take people who matters to places where TPM already successfully implemented.

STEP 3 - Setting up TPM and departmental committees :

TPM includes improvement, autonomous maintenance, quality maintenance etc., as part of it. When
committees are set up it should take care of all those needs.

STEP 4 - Establishing the TPM working system and target :

Now each area is benchmarked and fix up a target for achievement.

STEP 5 - A master plan for institutionalizing :

Next step is implementation leading to institutionalizing wherein TPM becomes an organizational culture.
Achieving PM award is the proof of reaching a satisfactory level.

STEP B - INTRODUCTION STAGE

This is a ceremony and we should invite all. Suppliers as they should know that we want quality supply
from them. Related companies and affiliated companies who can be our customers, sisters concerns etc.
Some may learn from us and some can help us and customers will get the communication from us that
we care for quality output.

STAGE C - IMPLEMENTATION

In this stage eight activities are carried which are called eight pillars in the development of TPM activity.
Of these four activities are for establishing the system for production efficiency, one for initial control
system of new products and equipment, one for improving the efficiency of administration and are for
control of safety, sanitation as working environment.
STAGE D - INSTITUTIONALISING STAGE

By all there activities one would has reached maturity stage. Now is the time for applying for PM award.
Also think of challenging level to which you can take this movement.

Organization Structure for TPM Implementation :

Pillars of TPM

PILLAR 1 - 5S :

TPM starts with 5S. Problems cannot be clearly seen when the work place is unorganized. Cleaning and
organizing the workplace helps the team to uncover problems. Making problems visible is the first step of
improvement.

Japanese Term English Translation Equivalent 'S' term

Seiri Organisation Sort

Seiton Tidiness Systematise

Seiso Cleaning Sweep

Seiketsu Standardisation Standardise

Shitsuke Discipline Self - Discipline

SEIRI - Sort out :

This means sorting and organizing the items as critical, important, frequently used items, useless, or
items that are not need as of now. Unwanted items can be salvaged. Critical items should be kept for use
nearby and items that are not be used in near future, should be stored in some place. For this step, the
worth of the item should be decided based on utility and not cost. As a result of this step, the search time
is reduced.

Priority Frequency of Use How to use

Throw away, Store away from the

Low Less than once per year, Once per year<
workplace

At least 2/6 months, Once per month,

Average Store together but offline
Once per week

High Once Per Day Locate at the workplace

SEITON - Organise :

The concept here is that "Each items has a place, and only one place". The items should be placed back
after usage at the same place. To identify items easily, name plates and colored tags has to be used.
Vertical racks can be used for this purpose, and heavy items occupy the bottom position in the racks.

SEISO - Shine the workplace :

This involves cleaning the work place free of burrs, grease, oil, waste, scrap etc. No loosely hanging
wires or oil leakage from machines.

SEIKETSU - Standardization :

Employees has to discuss together and decide on standards for keeping the work place / Machines /
pathways neat and clean. This standards are implemented for whole organization and are tested /
Inspected randomly.

SHITSUKE - Self discipline :

Considering 5S as a way of life and bring about self-discipline among the employees of the organization.
This includes wearing badges, following work procedures, punctuality, dedication to the organization etc.

PILLAR 2 - JISHU HOZEN ( Autonomous maintenance ) :

This pillar is geared towards developing operators to be able to take care of small maintenance tasks,
thus freeing up the skilled maintenance people to spend time on more value added activity and technical
repairs. The operators are responsible for upkeep of their equipment to prevent it from deteriorating.
Policy :

1. Uninterrupted operation of equipments.

2. Flexible operators to operate and maintain other equipments.
3. Eliminating the defects at source through active employee participation.
4. Stepwise implementation of JH activities.

JISHU HOZEN Targets:

1. Prevent the occurrence of 1A / 1B because of JH.

2. Reduce oil consumption by 50%
3. Reduce process time by 50%
4. Increase use of JH by 50%

Steps in JISHU HOZEN :

1. Preparation of employees.
2. Initial cleanup of machines.
3. Take counter measures
4. Fix tentative JH standards
5. General inspection
6. Autonomous inspection
7. Standardization and
8. Autonomous management.

Each of the above mentioned steps is discussed in detail below.

1. Train the Employees : Educate the employees about TPM, Its advantages, JH advantages and Steps in JH.
Educate the employees about abnormalities in equipments.
2. Initial cleanup of machines :
o Supervisor and technician should discuss and set a date for implementing step1
o Arrange all items needed for cleaning
o On the arranged date, employees should clean the equipment completely with the help of
maintenance department.
o Dust, stains, oils and grease has to be removed.
o Following are the things that has to be taken care while cleaning. They are Oil leakage, loose
wires, unfastened nits and bolts and worn out parts.
o After clean up problems are categorized and suitably tagged. White tags is place where problems
can be solved by operators. Pink tag is placed where the aid of maintenance department is
needed.
o Contents of tag is transferred to a register.
o Make note of area which were inaccessible.
o Finally close the open parts of the machine and run the machine.
3. Counter Measures :
o Inaccessible regions had to be reached easily. E.g. If there are many screw to open a fly wheel
door, hinge door can be used. Instead of opening a door for inspecting the machine, acrylic sheets
can be used.
 o To prevent work out of machine parts necessary action must be taken.
o Machine parts should be modified to prevent accumulation of dirt and dust.
4. Tentative Standard :
o JH schedule has to be made and followed strictly.
o Schedule should be made regarding cleaning, inspection and lubrication and it also should include
details like when, what and how.
5. General Inspection :
o The employees are trained in disciplines like Pneumatics, electrical, hydraulics, lubricant and
coolant, drives, bolts, nuts and Safety.
o This is necessary to improve the technical skills of employees and to use inspection manuals
correctly.
o After acquiring this new knowledge the employees should share this with others.
o By acquiring this new technical knowledge, the operators are now well aware of machine parts.
6. Autonomous Inspection :
o New methods of cleaning and lubricating are used.
o Each employee prepares his own autonomous chart / schedule in consultation with supervisor.
o Parts which have never given any problem or part which don't need any inspection are removed
from list permanently based on experience.
o Including good quality machine parts. This avoid defects due to poor JH.
o Inspection that is made in preventive maintenance is included in JH.
o The frequency of cleanup and inspection is reduced based on experience.
7. Standardization :
o Upto the previous stem only the machinery / equipment was the concentration. However in this
step the surroundings of machinery are organized. Necessary items should be organized, such that
there is no searching and searching time is reduced.
o Work environment is modified such that there is no difficulty in getting any item.
o Everybody should follow the work instructions strictly.
o Necessary spares for equipments is planned and procured.
8. Autonomous Management :
o OEE and OPE and other TPM targets must be achieved by continuous improve through Kaizen.
o PDCA ( Plan, Do, Check and Act ) cycle must be implemented for Kaizen.

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 involve all people in the organization. Kaizen is opposite to big
spectacular innovations. Kaizen requires no or little investment. The principle behind is that "a very large
number of small improvements are move effective in an organizational environment than a few
improvements of large value. This pillar is aimed at reducing losses in the workplace that affect our
efficiencies. By using a detailed and thorough procedure we eliminate losses in a systematic method
using various Kaizen tools. These activities are not limited to production areas and can be implemented in
administrative areas as well.

Kaizen Policy :

1. Practice concepts of zero losses in every sphere of activity.

2. relentless pursuit to achieve cost reduction targets in all resources
 3. Relentless pursuit to improve over all plant equipment effectiveness.
4. Extensive use of PM analysis as a tool for eliminating losses.
5. Focus of easy handling of operators.

Kaizen Target :

Achieve and sustain zero loses with respect to minor stops, measurement and adjustments, defects and
unavoidable downtimes. It also aims to achieve 30% manufacturing cost reduction.

Tools used in Kaizen :

1. PM analysis
2. Why - Why analysis
3. Summary of losses
4. Kaizen register
5. Kaizen summary sheet.

The objective of TPM is maximization of equipment effectiveness. TPM aims at maximization of machine
utilization and not merely machine availability maximization. As one of the pillars of TPM activities, Kaizen
pursues efficient equipment, operator and material and energy utilization, that is extremes of productivity
and aims at achieving substantial effects. Kaizen activities try to thoroughly eliminate 16 major losses.

16 Major losses in a organisation:

Loss Category

1. Failure losses - Breakdown loss

2. Setup / adjustment losses
3. Cutting blade loss
4. Start up loss
Losses that impede equipment efficiency
5. Minor stoppage / Idling loss.
6. Speed loss - operating at low speeds.
7. Defect / rework loss
8. Scheduled downtime loss

9. Management loss
10. Operating motion loss
11. Line organization loss Loses that impede human work efficiency
12. Logistic loss
13. Measurement and adjustment loss

14. Energy loss

15. Die, jig and tool breakage loss Loses that impede effective use of production resources
16. Yield loss.
Classification of losses :

Aspect Sporadic Loss Chronic Loss

Causes for this failure can be This loss cannot be easily identified
Causation
easily traced. Cause-effect and solved. Even if various counter
relationship is simple to trace. measures are applied

This type of losses are caused

Remedy Easy to establish a remedial
because of hidden defects in
measure
machine, equipment and methods.

A single cause is rare - a

Impact / Loss
A single loss can be costly combination of causes trends to be
a rule

Frequency of The frequency of occurrence is

The frequency of loss is more.
occurrence low and occasional.

Usually the line personnel in the Specialists in process engineering,

Corrective action production can attend to this quality assurance and maintenance
problem. people are required.

PILLAR 4 - PLANNED MAINTENANCE :

It is aimed to have trouble free machines and equipments producing defect free products for total
customer satisfaction. This breaks maintenance down into 4 "families" or groups which was defined
earlier.

1. Preventive Maintenance
2. Breakdown Maintenance
3. Corrective Maintenance
4. Maintenance Prevention

With Planned Maintenance we evolve our efforts from a reactive to a proactive method and use trained
maintenance staff to help train the operators to better maintain their equipment.

Policy :

1. Achieve and sustain availability of machines

2. Optimum maintenance cost.
3. Reduces spares inventory.
4. Improve reliability and maintainability of machines.

Target :

1. Zero equipment failure and break down.

2. Improve reliability and maintainability by 50 %
 3. Reduce maintenance cost by 20 %
4. Ensure availability of spares all the time.

Six steps in Planned maintenance :

1. Equipment evaluation and recoding present status.

2. Restore deterioration and improve weakness.
3. Building up information management system.
4. Prepare time based information system, select equipment, parts and members and map out plan.
5. Prepare predictive maintenance system by introducing equipment diagnostic techniques and
6. Evaluation of planned maintenance.

PILLAR 5 - QUALITY MAINTENANCE :

It is aimed towards customer delight through highest quality through defect free manufacturing. Focus is
on eliminating non-conformances in a systematic manner, much like Focused Improvement. 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 (Quality Control
to Quality Assurance).

QM activities is to set equipment conditions that preclude quality defects, based on the basic concept of
maintaining perfect equipment to maintain perfect quality of products. The condition are checked and
measure in time series to very that measure values are within standard values to prevent defects. The
transition of measured values is watched to predict possibilities of defects occurring and to take counter
measures before hand.

Policy :

1. Defect free conditions and control of equipments.

2. QM activities to support 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.

Target :

1. Achieve and sustain customer complaints at zero

2. Reduce in-process defects by 50 %
3. 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

Data related to product :

1. Product wise defects

2. Severity of the defect and its contribution - major/minor
3. Location of the defect with reference to the layout
4. Magnitude and frequency of its occurrence at each stage of measurement
5. Occurrence trend in beginning and the end of each production/process/changes. (Like pattern change,
ladle/furnace lining etc.)
6. Occurrence trend with respect to restoration of breakdown/modifications/periodical replacement of quality
components.

Data related to processes:

1. The operating condition for individual sub-process related to men, method, material and machine.
2. The standard settings/conditions of the sub-process
3. The actual record of the settings/conditions during the defect occurrence.

PILLAR 6 - TRAINING :

It is aimed to have multi-skilled revitalized employees whose morale 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. It is not sufficient know only "Know-How" by they should also learn "Know-why". By
experience they gain, "Know-How" to overcome a problem what to be done. This they do without knowing
the root cause of the problem and why they are doing so. Hence it become necessary to train them on
knowing "Know-why". The employees should be trained to achieve the four phases of skill. The goal is to
create a factory full of experts. 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.

Policy :

1. Focus on improvement of knowledge, skills and techniques.

2. Creating a training environment for self learning based on felt needs.
3. Training curriculum / tools /assessment etc conductive to employee 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.

Steps in Educating and training activities :

1. Setting policies and priorities and checking present status of education and training.
 2. Establish of training system for operation and maintenance skill up gradation.
3. Training the employees for upgrading the operation and maintenance skills.
4. Preparation of training calendar.
5. Kick-off of the system for training.
6. Evaluation of activities and study of future approach.

PILLAR 7 - OFFICE TPM :

Office TPM should be started after activating four other pillars of TPM (JH, KK, QM, PM). Office TPM
must be followed to improve productivity, efficiency in the administrative functions and identify and
eliminate losses. This includes analyzing processes and procedures towards increased office automation.
Office TPM addresses twelve major losses. They are

1. Processing loss
2. Cost loss including in areas such as procurement, accounts, marketing, sales leading to high inventories
3. Communication loss
4. Idle loss
5. Set-up loss
6. Accuracy loss
7. Office equipment breakdown
8. Communication channel breakdown, telephone and fax lines
9. Time spent on retrieval of information
10. Non availability of correct on line stock status
11. Customer complaints due to logistics
12. Expenses on emergency dispatches/purchases

How to start office TPM ?

A senior person from one of the support functions e.g. Head of Finance, MIS, Purchase etc should be
heading the sub-committee. Members representing all support functions and people from Production &
Quality should be included in sub committee. TPM co-ordinate plans and guides the sub committee.

1. Providing awareness about office TPM to all support departments

2. Helping them to identify P, Q, C, D, S, M in each function in relation to plant performance
3. Identify the scope for improvement in each function
4. Collect relevant data
5. Help them to solve problems in their circles
6. Make up an activity board where progress is monitored on both sides - results and actions along with
Kaizens.
7. Fan out to cover all employees and circles in all functions.

Kobetsu Kaizen topics for Office TPM :

Inventory reduction
Lead time reduction of critical processes
Motion & space losses
 Retrieval time reduction.
Equalizing the work load
Improving the office efficiency by eliminating the time loss on retrieval of information, by achieving zero
breakdown of office equipment like telephone and fax lines.

Office TPM and its Benefits :

1. Involvement of all people in support functions for focusing on better plant performance
2. Better utilized work area
3. Reduce repetitive work
4. Reduced inventory levels in all parts of the supply chain
5. Reduced administrative costs
6. Reduced inventory carrying cost
7. Reduction in number of files
8. Reduction of overhead costs (to include cost of non-production/non capital equipment)
9. Productivity of people in support functions
10. Reduction in breakdown of office equipment
11. Reduction of customer complaints due to logistics
12. Reduction in expenses due to emergency dispatches/purchases
13. Reduced manpower
14. Clean and pleasant work environment.

P Q C D S M in Office TPM :

P - Production output lost due to want of material, Manpower productivity, Production output lost due to
want of tools.

Q - Mistakes in preparation of cheques, bills, invoices, payroll, Customer returns/warranty attributable to

BOPs, Rejection/rework in BOP's/job work, Office area rework.

C - Buying cost/unit produced, Cost of logistics - inbound/outbound, Cost of carrying inventory, Cost of
communication, Demurrage costs.

D - Logistics losses (Delay in loading/unloading)

Delay in delivery due to any of the support functions

Delay in payments to suppliers
Delay in information

S - Safety in material handling/stores/logistics, Safety of soft and hard data.

M - Number of kaizens in office areas.

How office TPM supports plant TPM :

Office TPM supports the plant, initially in doing Jishu Hozen of the machines (after getting training of
Jishu Hozen), as in Jishu Hozen at the
 1. Initial stages machines are more and manpower is less, so the help of commercial departments can be
taken, for this
2. Office TPM can eliminate the lodes on line for no material and logistics.

Extension of office TPM to suppliers and distributors :

This is essential, but only after we have done as much as possible internally. With suppliers it will lead to
on-time delivery, improved 'in-coming' quality and cost reduction. With distributors it will lead to accurate
demand generation, improved secondary distribution and reduction in damages during storage and
handling. In any case we will have to teach them based on our experience and practice and highlight
gaps in the system which affect both sides. In case of some of the larger companies, they have started to
support clusters of suppliers.

PILLAR 8 - SAFETY, HEALTH AND ENVIRONMENT :

Target :

1. Zero accident,
2. Zero health damage
3. Zero fires.

In this area focus is on to create a safe workplace and a surrounding area that is not damaged by our
process or procedures. This pillar will play an active role in each of the other pillars on a regular basis.

A committee is constituted for this pillar which comprises representative of officers as well as workers.
The committee is headed by Senior vice President ( Technical ). Utmost importance to Safety is given in
the plant. Manager (Safety) is looking after functions related to safety. To create awareness among
employees various competitions like safety slogans, Quiz, Drama, Posters, etc. related to safety can be
organized at regular intervals.

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.
Development of TPM
Total productive maintenance (TPM) is one of the foundation blocks of any lean
manufacturing implementation; after all it is not possible to improve our processes if we
cannot rely on our equipment and machines. Combined with 5S; TPM provides a firm
foundation on which to build sustainable improvements to our business.

After world war two many companies in the US were starting to use preventative
maintenance and even some forms of predictive maintenance techniques to try to
improve the reliability of their machinery which on the whole was maintained through a
maintenance department.

Total Productive Maintenance as we know it today was developed at a company called

Nippondenso (an important supplier of Toyota.) who looked at what the American
companies were doing and tried to combine with aspects of what at the time was called
total quality control (TQC). TQC has since become what we call total quality
management (TQM) and was found not fit very well with the maintenance methods that
they were trying to implement.

Therefore they adapted the TQM methods to better fit with their requirements and
created total productive maintenance (TQM); a maintenance program that involves all
with the organization just as TQM does. Also similar to TQM in that many of the
responsibilities for day to day activities are placed into the hands of the operators and
they became more involved in the actual maintenance of the machine freeing the
experts to do more preventative works. TQM and TPM also focus very much on the
prevention of problems rather than firefighting after the event.
Maintenance Programs

Maintenace Programs

Below are descriptions of maintenance methods that can be implemented alone or

integrated within the TPM program.

Breakdown maintenance
Breakdown maintenance is maintenance that is done after the event, we wait for the
machine to break down before we take any action. Whilst this is far from ideal it still has
its place if machinery that fails is quick and easy to repair inexpensively without
impacting on production.
Preventive maintenance
Preventative maintenance can be thought of as being like taking your car for a service;
we service each machine based either on the time passed or the number of cycles
completed; conducting inspections and component replacements as specified by the
manufacturers or past experience. Whilst this helps to maintain equipment in an
optimum condition we often find ourselves replacing components that appear to be
perfectly fine just in case they fail in the near future.

Predictive maintenance

Infrared Analysis

Predictive maintenance builds on preventive maintenance and uses techniques such as

infrared thermal imaging, vibration analysis and oil analysis to try to highlight
components that have begun to wear and are likely to fail. Through these techniques we
can prolong the use of components that may otherwise have been just replaced at a
regular service and potentially save significant sums of money as well as highlight other
problems that may not be caught at all by standard preventive maintenance.
Corrective Maintenance
Corrective maintenance is very much part of TPM, we improve machines to make them
easier to clean and maintain; this may involve the rerouting of parts of the machines
such as lubrication pipes to make them easier to monitor and maintain, or modifying the
machine to prevent the creation or ingress of dirt inside the machine. The aim of
corrective maintenance is to help those responsible for conducting the maintenance and
monitoring the machines to do it easily and safely and efficiently.

Maintenance prevention
Through the analysis of maintenance data the maintenance technicians can work with
the designers of our machines to create machines that are more reliable. Maintenance
and repairs that are required can be made as simple and as easy as possible to reduce
time, save money and improve safety.

Autonomous maintenance
The involvement of the operators in TPM just as in TQM shows itself
through autonomous maintenance, independent maintenance carried out by the
operators themselves rather than the traditional we run the machines, maintenance fix
them attitude. The operators become responsible for the day to day maintenance of the
machines with regards to things like lubrication and bolt tightening as well as in some
case minor repairs and replacements. This frees the maintenance technicians to
become more involved in making improvements to improve machines reliability and
maintainability.
TPM Video

OEE six big losses

Overall equipment effectiveness or OEE is a very important measure within TPM. One
of the main aims of TPM is to reduce the six big losses;

1. Breakdowns
2. Setup and Adjustment losses
3. Idling and minor stoppages
4. Reduced Speed
5. Defects and rework
6. Start-up losses

These losses refer to more than just breakdowns of the machines, they also refer to the
quality of product produced and to how efficiently we set up the machines and run them
forcing us to improve every aspect of the machine through lean manufacturing tools
such as PokaYoke and SMED (Single Minute Exchange of Die.) OEE is calculated from
these six losses and gives us an overall picture of the efficiency of each individual
machine or piece of equipment. This allows us to focus our improvement efforts where
they are needed most.
 What Is Total Productive Maintenance?

How to alleviate downtime and boost production

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Youre only as strong as your weakest link. Although trite, the phrase embodies what manufacturing
plants and processing facilities have worked to overcome for years: How do you plan for and prevent
broken equipment in your lean production culture?
Another trite phrase hints at the answer: The weakest link is the strongest because it can break the
chain.

Preventive and routine maintenance models help alleviate downtime and boost overall production.
The most popular method is Total Productive Maintenance (TPM).

TPM brings maintenance into focus as a vital part of business. Maintenance downtime is included in
manufacturing scheduling, and in many cases becomes an integral part of the manufacturing
process. TPM assigns the responsibility for preventive and routine maintenance to the same people
who operate a particular piece of equipment, which puts the people most familiar with the machine
in charge of its care.

TPM is similar to 5S, which creates effective workplace organization and standardized procedures to
improve safety, quality, productivity, and employee attitude.

In the most basic sense, the three goals of TPM are:

1. Zero unplanned failures
2. Zero product defects
3. Zero accidents

The eight pillars of TPM

As with the entire body of lean manufacturing systems, TPM originated in Japan. An organization
called the Japan Institute of Plant Maintenance (JIPM) formed in 1961 (although under a different
moniker), and unveiled the TPM concept a decade later. Seiichi Nakajima of JIPM established the
eight management pillars of TPM, and Japanese automotive supplier Nippondenso is first credited
with using the process.

TPM aims to increase productivity, efficiency, and safety by empowering operators and team leaders
to play a proactive role in day-to-day lubrication, inspection, and cleaning. Management is tasked
with creating a buy-in culture to support continuous activities through the eight pillars of activity.

The eight pillars of TPM are:

1. Autonomous maintenance: Operators monitor the condition of their own equipment and
work areas.
2. Process and machine improvement: Team leaders collect information from operators and
work areas, then prioritize preventive maintenance and improvements.
3. Preventive maintenance: Operators and team leaders share preventive maintenance tasks and
schedules.
4. Early management of new equipment: Team leaders anticipate and plan for parts relative to
equipment life cycles.
5. Process quality management: Shared responsibility for operation and maintenance
encourages quality improvement ideas from all areas of work.
6. Administrative work: Managers prioritize data from the previous pillars and share outcomes
with team leaders and work areas.
 7. Education and training: Continuous improvement includes operator education and training
which improves morale, retention, and efficiency.
8. Safety and sustained success: Facilitywide safety is prioritized, which positively affects
sustained success of the TPM program.

Because maintenance is traditionally considered an inevitable and not-for-profit function, TPM is

considered the most difficult lean manufacturing tool to implement. Shifting cultural beliefs within a
facility, from the CEO to machinists and janitors, might take years, but the payoff for both the
finished product and employee morale is worth the investment.

Japan Institute of Plant Maintenance

JIMP still operates today, as both a survey and research facility testing TPM technologies. The
organization is currently researching equipment aging in relation to state-of-the-art maintenance
technology and repair.

How to implement Total Productive

Maintenance

David McBride
Tags: maintenance and reliability, total productive maintenance, lean manufacturing

As we conduct lean assessments at manufacturing facilities throughout the region, I have

noticed organizations increasingly embracing lean concepts. But one key area that often
falls by the wayside is equipment maintenance. I repeatedly see facilities in which there is a
complacent attitude about equipment maintenance and reliability. Equipment is expected
to fail. Maintenance is primarily reactive. Where they exist, preventive maintenance plans
are sketchy, often ignored, and not used because were experienced. Large inventories of
spare parts are stored in conditions that significantly reduce their useful life. Operators
ignore the early warning signs of pending failure. Furthermore, I always hear at least 10
reasons why we cant change the way we do things around here.

What if other industries took the same path as these organizations? Take, for example, the
aircraft maintenance industry. There is a high degree of discipline from the certifications of
those who perform the maintenance to the suppliers of parts and materials used on the job.
Procedures are very specific, and every process and step is documented. Consequently, with
more than 27,000 takeoffs and landings every day in the United States, aircraft crashes due
to equipment failure rarely happen. Another good example is NASCAR Winston Cup racing.
The best-of-the-best in stock car racing depend on reliable equipment to do their job; every
race car must meet rigid safety guidelines and has to be reliable. The old saying in the pits
is: If you cant finish, you cant win. Achieving 100 percent reliability takes discipline and
teamwork. Organizations that want to compete and become world class need to
successfully implement Total Productive Maintenance (TPM) programs.

TPM requires effective leadership from the start. That is part of the meaning of total in
Total Productive Maintenance. Without effective leadership that links TPM efforts to the
business and holds people accountable for performing highly specified work, equipment
performance and reliability will continue to decline and TPM initiatives will be short-lived.
Many of todays business leaders have risen through the ranks when maintenance was only
responsible for fixing things not for preventing problems. Viewing maintenance as a
non-value-adding support function, they often subject the maintenance department to
severe cost-cutting; this usually results in higher costs due to decreased equipment
effectiveness.

Companies that have been successful usually follow an implementation plan that includes
the following 12 steps:

Step 1:Announcement of TPM. Top management needs to create an environment that

will support the introduction of TPM. Without the support of management, skepticism and
resistance will kill the initiative.
Step 2:Launch a formal education program. This program will inform and educate
everyone in the organization about TPM activities, benefits and the importance of
contribution from everyone.

Step 3:Create an organizational support structure. This group will promote and sustain
TPM activities once they begin. Team-based activities are essential to a TPM effort. This
group needs to include members from every level of the organization from management
to the shop floor. This structure will promote communication and will guarantee everyone is
working toward the same goals.

Step 4:Establish basic TPM policies and quantifiable goals. Analyze the existing
conditions and set goals that are SMART: Specific, Measurable, Attainable, Realistic and
Time-based.

Step 5:Outline a detailed master deployment plan. This plan will identify what
resources will be needed and when for training, equipment restoration and improvements,
maintenance management systems and new technologies.

Step 6: TPM kick-off. Implementation will begin at this stage.

Step 7: Improve the effectiveness of each piece of equipment. Project teams will
analyze each piece of equipment and make the necessary improvements.

Step 8 :Develop an autonomous maintenance program for operators. Operators

routine cleaning and inspection will help stabilize conditions and stop accelerated
deterioration.

Step 9:Develop a planned or preventive maintenance program. Create a schedule for

preventive maintenance on each piece of equipment.

Step 10:Conduct training to improve operation and maintenance skills. The

maintenance department will take on the role of teachers and guides to provide training,
advice and equipment information to the teams.

Step 11:Develop an early equipment management program. Apply preventive

maintenance principles during the design process of equipment.

Step 12:Continuous improvement. As in any lean initiative, the organization needs to

develop a continuous improvement mind-set.

Maintenance and reliability as a core business strategy is key to a successful TPM

implementation. Without the support of top management, TPM will be just another flavor of
the month. Implementing TPM using the above 12 steps will start you on the road to zero
breakdowns and zero defects.
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About the author:

David McBride is co-founder of EMS Consulting Group ( http://www.emsstrategies.com), a
Carlsbad, Calif.-based engineering and management consulting firm. David has a bachelors
of science degree in mechanical engineering from Ohio State University. He has a successful
track record in the development and implementation of Failure Modes and Effects Analysis
and Design for Manufacturability programs at several organizations and has greatly reduced
manufacturing costs through the utilization of lean manufacturing, kaizen events and
manufacturing system analysis. He has also been highly successful at developing and
executing new product introduction processes, and staffing and capital equipment plans. To
contact David about this article, send an e-mail to [email protected].

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