TOTAL PRODUCTIVE MAINTENANCE

(T.P.M)
“TPM is productive maintenance
involving Total Participation”
Total Productive Maintenance (TPM)

TPM is a productive maintenance implemented by all employees in an organisation.

TPM involves everyone in the organiation from operators to senior management in

Equipment improvement.
 TPM PSYCHOLOGY

Health of a Child Mother

Doctor Father

Management
Health of a Machine Operator Maintenance
T-P-M in three words

T - TOTAL All individual in the organisation working together.

Production of goods that meet or exceed customer's

P - PRODUCTIVE expectation

Keeping equipment and plant in good condition

M - MAINTENANCE
at all times.
Total Productive Maintenance (TPM)

History of TPM

-This is an innovative Japanese concept.

-Developed in 1951.

-Nippondenso is the 1st company that implemented TPM in 1960.

-Based on these developments Nippondenso was awarded the distinguished plant

prize for developing & implementing TPM, by Japanese institute of Plant engineers
(JIPE)

-Nippondenso becomes 1st company to obtain the TPM certificate.

Total Productive Maintenance (TPM)

Goals of TPM

-Increase production quality.

-Increase job satisfaction.

-Using teams for continuous improvement.

-Improve state of maintenance.

-Empower employees.
Total Productive Maintenance (TPM)

Why TPM :

-Avoid wastage in quickly changing economic environment.

-Reduce cost of production.

-Produce a low batch quantity at the earliest time.

-Goods send to customer must be non- defective.

Total Productive Maintenance (TPM)

Within TPM there are five developmental activities:

1. Use small group activities to improve equipment effectiveness by

eliminating the major equipment related losses.
2. Involve the operators in daily maintenance activities to maintain basic
equipment conditions (daily cleaning, lubrication, inspection, Tightening )
3. Increase the efficiency and cost effectiveness of maintenance work
through better scheduling and management.
Total Productive Maintenance (TPM)

4. Training to improve the skills of all involved (operators, maintenance

mechanics; supervisors, management etc.)

5. An early equipment management program to prevent start up and / or

ongoing problems with new equipment (adopt a total life cycle cost
approach to equipment management)
 Pillars of TPM

Pillars of TPM

1 2 3 4 5 6

7
8
1. Autonomous maintenance, 2. Planned Maintenance, 3. Equipment and process improvement, 4. Early
management of new equipment , 5. process quality management, 6. TPM in office, 7. Education and
training, 8. Safety & environment Management.
Total Productive Maintenance (TPM)

Overview of Eight Pillars

Overview of 8 Pillars of TPM

1.Autonomous maintenance
Overview of 8 Pillars of TPM

1st Pillar - Autonomous maintenance

Objective :
To develop Self – management activities through Small groups.
To increase skill of operators & develop willingness to “Protect his own equipment by
himself/herself”

Activities :
Create awareness of Forced deterioration, identify & rectify abnormalities.
Develop standards for carrying out basic maintenance and maintain Basic conditions.
Develop Equipment Consciousness through education of machine & systems.
Standardize operations & prevent deterioration.
 Types of Deterioration

Natural Forced
Deterioration Deterioration

Ageing under Artificially Accelerated

Standard because of Non-Standard
Operating Operating Conditions
Conditions

Attracts
Breakdown !
 Overview of 8 Pillars of TPM

2nd Pillar - Planned maintenance

Aim : Realise efficiency in maintenance department to

eliminate all losses

Method: Daily maintenance

TBM, CBM, Improvement for increasing the service life expectancy, control for
replacement of parts, failure analysis and prevention of re-occurrence, Lubrication
control

Who : Operator and maintenance men

 Overview of 8 Pillars of TPM

3rd Pillar - Equipment & Process Improvement

Aim :
•To focus on specific losses & Increase productivity, ease of operation &
Standardization of methods
•To ensure adequate methods for identification of losses & countermeasure
implementation
•To increase ease of detecting / correcting deterioration of equipment

Method: Repeated Equipment Breakdown Analysis & Countermeasures,

CAPA-Do for Minor Stoppages, CAPA-Do for Change-over, CAPA-Do for
Defects
Who: Operator and Technical Services Group
 Overview of 8 Pillars of TPM

4th Pillar – Early Management of New Equipment.

Aim : Shorten the trial period for new product, design of new equipment, and run-
up time for stable launching of products.

Method:
• Easy to maintain and reliable equipment.
• Review of design methodologies.

Who : R & D / Production Engg Staff .

 Overview of 8 Pillars of TPM

5th Pillar - Process Quality Management.

Aim : Realise ‘Zero’ defects through observing the required equipment maintenance

Method: Conformation to the standards for quality characteristics and recognise the
defect symptom and actual defect record. Assure product quality, investigate the unit
process material and energy utilisation of equipment condition and production
methods.Investigation, analysis and do kaizens in such conditions . (QRQC)

Who: Staff and cell line or leaders

 Overview of 8 Pillars of TPM

6th Pillar – TPM in office.

Aim : Realise Zero functional loss, Organise high efficiency loss, Render service and
support function to the service departments

Method: By 5 pillar activities

Who : Members of sales and administrative & finance departments

 Overview of 8 Pillars of TPM

7th Pillar – Education and Training.

Aim : Raise the technical skill level of operators and maintenance men

Method: Basic maintenance steps- nuts & bolts - key mating - Bearings- Gear
Transmission- Leakage prevention- Hydraulics & Pneumatic equipment - Electrical
control systems
TPM

Who : Operators and maintenance

 Overview of 8 Pillars of TPM

8th pillar- Safety and Environment Management

Aim : Attain and keep the Zero accident level, Create a healthy and clean working area

Method: Safety measures to protect the operators from equipment accidents, Make the
operation safe, Improve the working environment - noise, dust, Measures to achieve
environment protection. Attention to the health and hygiene of the employees promotion
of cheerful working environment.

Who: Managers & staff

 TPM

Key Points For Success In Implementation

u Cooperation Between All Departments

u Maintenance understanding and support
u Lead By Work Teams
u Operator Input and Decision on Check Sheet Items
u TPM Activities Become Part Of The Daily Routine
u Quick Repair
u TPM Meetings
u Step System
u Step Audit
u Promote Success Stories
TPM
Leak

Gasket
Cracked

Lubrication Process

Root Cause

Why This Leak? Gasket cracked New Gasket

Why Gasket cracked? Installed wrong Install Correctly

TPM Why Installed wrong? No Tool provided Provide Tool

Installation
Why no Tool provided? No procedural call-up
Procedure
 TPM

TPM promotion

1. Special committees at every level to promote TPM

2. Newsletter.
3. Articles
4. Videos
5. Posters.
Total Productive Maintenance (TPM)

TPM benefits :

- Increase productivity.

- Reduced equipment downtime.

- Increase plant capacity

- Lower maintenance & production cost.

- Approaching zero equipment defects.

- Enhance job satisfaction.

- Increase return of investment (ROI)

 OEE
Over all Equipment Efficiency
 FORMULAES

OEE= [Availability rate × Performance rate × Quality rate]× 100

• Availability rate(A) = Total available time – Down time
Total available time

• Performance rate(P) = Actual Production

Target Production

• Quality rate (Q)= Actual Production- NC

Actual Production
• Mean time break down failure (MTBF)=

Total available time – total breakdown time

Numbers of breakdown

• Mean time to repair(MTR) =Total Breakdown time

No. of Breakdown
PM/PdM

Goals:
• Improve unit reliability, efficiency and safety through maintenance
efficiency using PM/PdM.
• Increase the ratio of PD/PdM hours to corrective maintenance hours to
reduce equipment down time.
• Reduce maintenance costs.
• Improve communication
• Foster system consistency.
• Identify benefits- CBA
PLANT MAINTENANCE
Plant Maintenance -

Maintenance of facilities and equipment in good working condition is

essential to achieve specified level of quality and reliability and efficient
working.

Plant maintenance is an important service function of an efficient

production system.

It helps in maintaining and increasing the costs and increasing the

effectiveness of production.
Plant Maintenance -
Importance –

1. To increase functional reliability of production facilities.

2. To maximize the useful life of the equipment.

3. To minimize the total production or operating costs directly adjusted, serviced and
operated equipment.

4. To minimize the frequency of interruptions to production by reducing breakdowns.

5. To maximize the production capacity from the given equipment resources.

6. To enhance the safety of manpower.

Plant Maintenance -

Types of Maintenance

1.Breakdown Maintenance.

2.Schedule Maintenance.

3.Preventive maintenance:
a.Periodic maintenance (TBM)
b. predictive maintenance.(CBM)

4.Maintenance prevention.
Plant Maintenance

Breakdown Maintenance –

It is an emergency based policy in which the plant of

equipment is operated until it fails and then it is brought back
into running condition by repair. The maintenance staff locate
any mechanical, electrical or any other fault to correct it imme
diately.
Breakdown Maintenance (Contd….) –

Typical causes for equipment breakdown.

1. Failure to replace worn out parts.

2. Lack of lubrication.
3. Neglected cooling system.
4. External such as too low or too high line voltage, wrong fuel etc.
5. Indifference towards equipment vibrations, unusual sounds coming out of
the rotating parts, equipment getting heated up etc.
FOUR REQUIREMENTS FOR ZERO BREAKDOWNS

1. Maintain basic equipment conditions

2. Restore deterioration
3. Correct design weaknesses
4. Improve technical skills

EXPOSE HIDDEN DEFECTS !!

IMPROVE EQUIPMENT EFFECTIVENESS !!
Plant Maintenance

Scheduled Maintenance

Scheduling of maintenance job basically deals with answering the two

questions
“ Who and when ”
Plant Maintenance

Scheduled Maintenance (Contd…) –

Realistic scheduling are the functions of realistic thinking, availability of data

and records. The scheduler should obtain knowledge about the following
facts before starting his job-

a. Availability of competent manpower.

b. Availability of equipments, spares and proper tools where the work is to be

carried out.

c. Starting data for the job and past schedules and charts.
Plant Maintenance

Preventive Maintenance

The preventive maintenance policy is a system of planned and

schedule maintenance.

The basic principal involved in this system is

“ prevention better than care”
Plant Maintenance

Preventive Maintenance (cont…) –

Preventive maintenance includes:

1. Proper identification of all items, their documentation and coding.

2. Inspection of plant and equipments at regular interval (Periodic inspection)
3. Proper Cleaning, lubrication of equipments.
4. To up keep the machine through minor repairs.
5. Failure analysis and planning for their estimation.
 Changing Our Attitudes
In many workshop, breakdowns, quality defects and rework are
always “Someone else’s fault”. This is a big problem.
Plant Maintenance

Preventive Maintenance (cont…)

Preventive maintenance schedules are normally of two categories.

a. Periodic maintenance (Time based maintenance)

b. Predictive Maintenance. (Condition based maintenance)

Plant Maintenance

Preventive Maintenance (cont…)

a. Periodic Maintenance (time based maintenance)

Time based maintenance consists of periodically inspecting, servicing and

cleaning equipment and replacing parts to prevent sudden failure and
process problems.

Benefits:
a. Extended life and use of the equipment.
b. Reliable production at the time when machine is needed most.
Plant Maintenance (cont…)-

b. Predictive Maintenance.

This is a method in which the service life of important part is expected based on inspection
or diagnostics, in order to use the parts to the limit of service life.
Compared to periodic maintenance, predictive maintenance is condition based maintenance.

Benefits:
• Increased plant readiness due to greater reliability of the equipment.
• Reduced expenditure for spare parts and labor.
• Reduces the probability of a machine experiencing failure, and this results in an
improvement in worker safety.
Plant Maintenance (cont…)-

4.Maintenance Prevention

• 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 easier in manufacturing ) and are incorporated before
commissioning a new equipment.
TQM

Total quality management (TQM) consists of organization-wide efforts to

install and make a permanent climate in which an organization

continuously improves its ability to deliver high-quality products and

services to customers.
 TQM

Similarities between TQM/TPM.

- Total commitment to the program by upper level management is required in both

program.

- Employees must be empowered to initiate corrective action, and a long range outlook
must be accepted, as TPM may take a year or more too implement.

- It is an on going process which is a continuous process improvement.

 TQM

Difference between TPM & TQM

Category TQM TPM

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

Mains of attaining goal Systematize the Employees participation.

management.

Target Quality or PPM Elimination of losses and

wastes.
 TPM

Conclusion

• TPM may be the only thing that stands between success and total failure for some
companies.

• It can be adopted to work not only in the industrial plants, but in construction, building
maintenance, transportation, and in variety of other situations.