Total Productive Maintainance (TPM)

TOTAL PRODUCTIVE
MAINTAINANCE(TPM)
BY:- MONGLAFRU MOG

SEMESTER:- 8TH
ROLL NO:- 28600720044
REG NO:-202860100720142
SUBJECT:- MAINTENANCE ENGINEERING(PE-ME802I)
B.TECH IN MECHANICAL ENGINEERING
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.
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.
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.

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
Component TPM Goal Type of Productivity Loss
Availability No Stops Availability takes into account Availability Loss, which includes all events that stop
planned production for an appreciable length of time (typically several minutes or
longer). Examples include Unplanned Stops (such as breakdowns and other down
events) and Planned Stops (such as changeovers).
Performance No Small Stops or Slow Running Performance takes into account Performance Loss, which includes all factors that
cause production to operate at less than the maximum possible speed when running.
Examples include both Slow Cycles, and Small Stops.
Quality No Defects Quality takes into account Quality Loss, which factors out manufactured pieces that
do not meet quality standards, including pieces that require rework. Examples
include Production Rejects and Reduced Yield on startup.
OEE Perfect Production OEE takes into account all losses (Availability Loss, Performance Loss, and Quality
Loss), resulting in a measure of truly productive manufacturing time.

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TOTAL PRODUCTIVE

BY:- MONGLAFRU MOG

2. Involve people in all levels of organization.

3. Form different teams to reduce defects and Self Maintenance.

2. Rectify customer complaints.

3. Reducethe manufacturing cost by 30%.

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.

STEP 5 - A master plan for institutionalizing :

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