TPM –
Total Productive Maintenance
An introduction
Presented by
Bülent Taşkıran
What is Total Productive Maintenance
(TPM) ?
the medical science of machines
a maintenance program which involves a
concept for maintaining plants and
equipment.
increasing production
increasing employee morale and job
satisfaction
TPM history
Toyota used to improve its global position
(1950s)
After TPM suppliers and customers were
involved
this next methodology was called lean
manufacturing
TPM - deterioration prevention
approach
approach
that
thataims
aimstotoidentify
identifyissues as
soon
issues
as possible
as soon as possible
plan
plantotoprevent
preventany
anyissues
issuesbefore
before
occurrence
occurrence
zero
zeroerror,
error,
zero
zero
work-related
work-related
accident,
accident,
and
zero
andloss
zero loss
Why TPM ?
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
How can TPM eliminate loss?
Equipment Six big losses
Available time 1 breakdowns
2 setup/adjustment
Available operating time
3 idlings/minor stoppages
Actual operating time 4 Speed
Effective operating time 5 defects in process and rework
6 Start up losses
Introduction of TPM into the
organization
Step A – Preparation
Announcement by Management
Initial education
Setting up TPM
Establishing the TPM working system
A master plan for institutionalizing
Introduction of TPM into the
organization
STEP B - INTRODUCTION
inviting suppliers and customers to the
conception
Communication for quality output
Introduction of TPM into the
organization
STAGE C – Implementation
8 activities/8 pillars in the development of TPM
establishing the system for production efficiency
initial control system of new products and
equipment
improving the efficiency of administration
control of safety
sanitation of working environment
Introduction of TPM into the
organization
Stage D - Institutionalising
TPM
TPM Office
Responsible
Autonomous Planned Individual
5S
Maintenance Maintenance Improvement
Quality Equipment Training People
Safety Development
Maintenance Maintenance
Pillars of TPM
Improve Overall Equipment Effectiveness
application of Total Productive
Maintenance’s (TPM) 8 Pillars
SAFETY, HEALTH AND
ENVIRONMENT
Office TPM
Training
Pillars of TPM
Quality Maintenance
5S
PLANNED MAINTENANCE
Kaizen
JISHU HOZEN
Autonomous maintenance
TPM starts with 5S
Sort
Sustain Straighten
Eliminate
waste
Standardize Sweep
[Pillar 1-5s] SEIRI - Sort out
This means sorting and organizing the items
as
critical
important
frequently used
useless
[Pillar 1-5s]
SEITON - Organise
Each items has a place, and only one
place
To identify items easily, name plates and
colored tags has to be used.
[Pillar 1-5s]
SEISO - Shine the workplace
cleaning the work place free of burrs,
grease, oil, waste, scrap etc.
No loosely hanging wires or oil leakage
from machines
[Pillar 1-5s]
SEIKETSU - Standardization
standardization for keeping the work place
/ machines / pathways neat and clean
implementation for whole organization and
testing / Inspectation randomly
[Pillar 1-5s]
SHITSUKE - Self discipline
Considering 5S as a way of life
self-discipline among the employees of the
organization
wearing badges
following work procedures
Punctuality
dedication to the organization
[Pillar 2-JISHU HOZEN]
Autonomous maintenance
developing operators to be able to take
care of small maintenance tasks
skilled maintenance people spending time
on more value added activity and technical
repairs
[Pillar 2-JISHU HOZEN]
Policy
uninterrupted operation of equipments
flexible operators to operate and maintain
other equipments
eliminating the defects at source through
active employee participation
Stepwise implementation of JH activities
[Pillar 2-JISHU HOZEN]
Targets
Increase use of JH by 50%
Reduce oil consumption by 50%
Reduce process time by 50%
PILLAR 3 - KAIZEN
"Kai" means change
"Zen" means good – better
kaizen is for small improvements
carried out on a continual basis
a very large number of small improvements are
move effective in an organizational environment
than a few improvements of large value
PILLAR 3 – KAIZEN
Policy
Practice concepts of zero losses in every
sphere of activity.
relentless pursuit to achieve cost reduction
targets in all resources
Relentless pursuit to improve over all plant
equipment effectiveness.
Extensive use of PM analysis as a tool for
eliminating losses.
Focus of easy handling of operators.
PILLAR 3 – KAIZEN
Target
Achieve and sustain zero loses with respect
to
minor stops
measurement and adjustments
defects
achieving 30% manufacturing cost
reduction
PILLAR 4 - PLANNED
MAINTENANCE
trouble free machines and equipments
producing defect free products for total
customer satisfaction
4 groups of maintenance
PILLAR 4 - PLANNED MAINTENANCE
groups of maintenance
Preventive Maintenance
Breakdown Maintenance
Corrective Maintenance
Maintenance Prevention
PILLAR 4 - PLANNED MAINTENANCE
Policy
Achieve and sustain availability of
machines
Optimum maintenance cost.
Reduces spares inventory.
Improve reliability and maintainability of
machines.
PILLAR 4 - PLANNED MAINTENANCE
Six steps of implementation
Equipment evaluation and recoding present status.
Restore deterioration and improve weakness.
Building up information management system.
Prepare time based information system, select
equipment, parts and members and map out plan.
Prepare predictive maintenance system by introducing
equipment diagnostic techniques and
Evaluation of planned maintenance.
PILLAR 5 –
QUALITY MAINTENANCE
customer delight through highest quality
through defect free manufacturing
focus on eliminating non-conformances in
a systematic manner
Transition is from reactive to proactive
(Quality Control to Quality Assurance)
PILLAR 5 - QUALITY MAINTENANCE
Policy
Defect free conditions and control of
equipments.
QM activities to support quality assurance.
Focus of prevention of defects at source
Focus on poka-yoke. ( fool proof system )
In-line detection and segregation of defects.
Effective implementation of operator quality
assurance.
PILLAR 5 - QUALITY MAINTENANCE
Target
Achieve and sustain customer
complaints at zero
Reduce in-process defects by 50 %
Reduce cost of quality by 50 %.
PILLAR 6 - TRAINING
multi-skilled revitalized employees
performing all required functions
effectively and independently
Training the employees to achieve four
steps of skills
PILLAR 6 – TRAINING
different phases of skills
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.
PILLAR 6 – TRAINING
Policy
Focus on improvement of knowledge, skills
and techniques.
Creating a training environment for self
learning based on felt needs.
Training curriculum / tools /assessment etc
conductive to employee revitalization
Training to remove employee fatigue and
make work enjoyable.
PILLAR 6 – TRAINING
Target
Achieve and sustain downtime due to
want men at zero on critical machines
Achieve and sustain zero losses due to
lack of knowledge / skills / techniques
Aim for 100 % participation in suggestion
scheme.
PILLAR 7 - 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
identify and eliminate losses
• analyzing processes and procedures towards increased
office automation
• twelve major losses
PILLAR 7 - OFFICE TPM
twelve major losses
Processing loss
Cost loss including in areas such as procurement,
accounts, marketing, sales leading to high inventories
Communication loss
Idle loss
Set-up loss
Accuracy loss
Office equipment breakdown
Communication channel breakdown, telephone and
fax lines
Time spent on retrieval of information
Non availability of correct on line stock status
Customer complaints due to logistics
Expenses on emergency dispatches/purchases
PILLAR 7 - OFFICE TPM
How office TPM supports plant TPM
supporting the plant, initially in doing
Autonomous maintenance (Jishu Hozen) of the
machines
Initial stages machines are more and
manpower is less, so the help of commercial
departments can be taken, for this
Office TPM can eliminate the lodes on line for
no material and logistics.
PILLAR 8 - SAFETY, HEALTH AND
ENVIRONMENT
Target
Zero accident,
Zero health damage
Zero fires.
active role in each of the other pillars
on a regular basis
Conclusion
TPM may be the only thing that stands
between success and total failure for some
companies
proven to be a program that works
can be adapted to work not only in
industrial plants, but in construction,
building maintenance, transportation
Questions
