WHAT IS TPM?

Medical science of machines. Newly defined concepts of maintaining plants and equipments. Brings maintenance into focus as a necessary and vitally important part of business.

WHY TPM
TPM was introduced to achieve the following objectives. Zero defect, Zero breakdown, Zero accident and Zero losses. Improving Overall Equipment Efficiency (OEE) for safe and efficient operation of the plant. Creating a clean and pleasant work environment leading to higher employee morale and greater operational profitability. TPM HISTORY Total Productive Maintenance has been introduced in Japan since 1951. Nippodenso was the first to introduce plant wide preventive maintenance in 1960. Based on the developments Nippodenso was awarded the distinguished plant prize for developing and implementing TPM, by the Japanese Institute of Plant Engineers(JIPE). Thus Nippodenso of the Toyota Group became the first to obtain TPM certification.

TYPES OF MAINTENANCE
1. 2. 3. Breakdown maintenance : Maintenance or rather repair work is carried out only after an equipment or machine has broken down. Preventive maintenance : Timely maintenance of equipments or machines; two types: Periodic maintenance : Regular or periodic maintenance of equipments or machines usually during a shutdown period. Predictive maintenance : Online monitoring of equipments or machines and prediction of a suitable maintenance schedule without affecting production. Corrective maintenance : A maintenance task performed to identify, isolate and rectify a fault so that the failed equipment , machine or system can be restored to an operational condition within the tolerances or limits established for in-service operations. Maintenance prevention : Machine engineering, designing or installation activities that is based on preventing the need for maintenance or for ease of maintenance.

4.

THE 8 PILLARS OF TPM

THE 8 PILLARS OF TPM contd..

1. 2. 3. 4. 5. Focussed Improvement(Kobetsu Kaizen): Continuously and even small steps of improvement and basically involves all people in the organisation. Autonomous maintenance(Jishu Hozen): Means maintaining ones equpment by oneself (for e.g. by the operator himself). Planned maintenance: Focusses on increasing availability of trouble-free machines and thereby producing quality products to ensure total customer satisfaction. Quality maintenance: This is the establishment of machine condition that will not allow the occurrence of defect and control of such is required to sustain zero defect. Development management (IFC): An early management procedure to critically review an equipment or process at the design stage itself with the objective of minimizing future maintenance cost and deterioration loss. Office TPM: To make an efficient working office that eliminates losses. Educational and training: Formation of autonomous workers who have the skill and technique for autonomous maintenance. Safety, Health and Environment: To create a safe and healthy workplace where accidents do not occur, no risk to health and the environment as a whole.

6. 7.

8.

Education & Training

OBJECTIVES
The primary objective of E&T programme is to develop a multi-skilled, revitalized workforce whose morale is high and has eagerness to come to work and perform all required functions effectively and independently. Enhance the know how as well as the know why and hence the overall development of the workforce.

INTRODUCTION
One of the eight pillars of Total Productive Maintenance (TPM) This programme needs to be started after the commitment by the top management to implement TPM. This programme in addition to technical knowledge incorporates the physiological and psychological aspects of the person concerned as well as the surrounding environment.

4 PHASES OF SKILL.
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.

STEPS IN EDUCATION AND TRAINING

Step 1 : Checking present status of education and training & setting policies and priorities Checking whether the existing method of imparting education for traditional maintenance technique is efficient enough. Set up policies like improvement of knowledge, skills and techniques. Creating a training environment for self learning based on felt needs. Training to remove employee fatigue and make work enjoyable. Step 2 : Establishment of training system for operation and maintenance and skill up gradation Organising seminars and lectures to create awareness about TPM and its advantages. Organising sessions on role of pillar Chairman and HODs by TPM consultant. Creating an awareness about 5S (seiri:sort out, seiton:organising, seiso:cleaning, seiketsu:standardardisation, shitsuke:self-discipline); which is the foundation for TPM implementation. Organising training sessions on all the pillars either by consultants or by experts in these fields if available in the same organisation. Preparing One Point Lessons and setting up display at the concerned locations. Preparing training manuals.

STEPS IN EDUCATION AND TRAINING contd

Step 3 : Preparation of training calendar Preparing a schedule for the various education and training programmes under TPM. Step 4 : Kick-off of the system for training Carrying out the training programmes as per schedule. Step 5 : Evaluation of activities and study of future approach At the end of a calendar period, carry out a review of the activities under TPM, by means of some tools like skill mapping sheet, management control report etc. Based on the results, prepare future plans for TPM implementation for the next calendar period.

A proper and effective E&T programme will ultimately act as a navigator for the other TPM pillars, and will result in the growth of an organisation in the long run.

TRAINING METHODS - TWO BROAD TYPES

ON THE JOB
Training is provided while they are conducting their regular works at the same places. Includes orientations, job instruction, apprenticeships, internships, assistantships, job rotation and coaching. Time saving as learning and working goes hand in hand.

OFF THE JOB

Basically class-room oriented. Includes lectures, special study, audio visual conferences or discussions, case studies, role playing, simulation, programmed instructions, and laboratory trainings. Quite an expensive means of providing training.

E&T TOOLS

One Point Lesson Skill Proficiency Level Sheet Management Control Report Monthly Assessment Sheet

COMPETENCY / SKILL PROFICIENCY LEVELS

0. NIL
I) Does not know anything ii) No Knowledge , No Awareness. Or

L0

1. BASIC (30% & below) i) Knows Theory but Cannot Perform (no practical) or - Can Perform (Knows Practical) but No Theory Knowledge. Or ii) Understands and utilizes terminology and standard practices. Has sufficient knowledge to handle standard tasks. Seeks guidance as appropriate.

L1

2. INTERMEDIATE (60% - 31%) i) Knows Theory & Can Perform to some extent (Needs Supervision). Or ii) Applies theories, concepts, principles and techniques to handle a broad range of tasks and situations with limited guidance. Exercises own judgement within the parameters of defined policies and practices.

L2

3. ADVANCED (80% - 61%) i) Knows Theory & Can Perform with Confidence (Needs No Supervision). Or ii) Demonstrates in-depth knowledge through the ability to resolve complex issues. Demonstrates knowledge of disciplines beyond own area of speciality, and keeps up-to-date with leading edge developments. Executes work independently and provides guidance

L3

4. EXPERT (100% - 81%)

i) Knows Theory, Can Perform with Confidence and Can Teach Others. Or ii) Demonstrates expert ability by solving complex problems that impact the strategic direction of the organization. Is seen as an expert or role model in this area, and imparts knowledge to others.

L4

MANAGEMENT CONTROL REPORT

TPM Pillar Progress Assessment : LDP Month: May Department Department Head Y Performance Trend Education And Training : D. S. Rekhi Sl. No. 1 2 3 4 5 6 7 8 Good H H H H H H H H KPI Nos. of Trainings (Deptt. Classroom ) during the month Unit Nos. Nos. Nos. Nos. Man hrs. / Emp. / Mth. Nos. Nos. Nos. Category Weightage Target A A A A A B B B 10 10 10 10 20 10 10 15 4.00 10 4 8 4.60 5 5 5 Actual 4 10 2 8 4.60 5 5 5 Scores# Scores (%) (Marks) 100% 100% 50% 100% 100% 100% 100% 100% 10.0 10.0 5.0 10.0 20.0 10.0 10.0 15.0 LDP Overall Rating* Brij Badhadra 92.50 A

Pillar Member: U C Mishra Is JH Training applicable (Y/N)

Nos. of Employees covered (Deptt. Classroom ) during the month

Nos. of Trainings (JH) during the month Nos. of Employees covered (JH) during the month Training Manhours. Nos. of On-The-Job Training during the month Nos. of Employees covered (On the job ) during the month Nos. of OPL's developed during the month

Pillar Meeting during the month

Nos.

50%

2.5

Monthly Assessment Sheet Department : BF-I & BF-II No. of Trainings Month Classroom On the job No. of Participants Classroom On the job

Annual target Monthly target

Achieved April 2012 Gap Cumulative Target Cumulative Achieved Cumulative Gap

18 2
4 2 2 4 2

7 1
1 0 1 1 0

288 24
21 -3 24 21 -3

78 7
9 3 7 9 2