DEFINITION

Maintenance is defined as the management, control, execution and quality assurance of activities which ensure the achievement of optimum availability and performance of a plant in order to meet business objectives.

TPM - MEANING

TPM is a partnership between the maintenance and production organization to improve product quality, reduce waste, reduce cost, increase equipment availability and improve maintenance state.

EVOLUTION OF MAINTENANCE
First Generation Fix it when it broke


Second Generation Third Generation Higher plant availability Longer equipment life Lower Costs


Higher plant reliability and availability Greater safety Better quality Longer equipment life Cost Effectiveness


1940

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2000

TYPES OF MAINTENANCE
Corrective (or) breakdown maintenance
It implies that repairs are made after failure of machine or equipment

Scheduled (or) Routine maintenance

It is a stitch-in-time procedure aimed to avoiding breakdowns

TYPES OF MAINTENANCE

Preventive maintenance
It is carried out before the failure arises (or) prior to the equipment actually breakdowns. E.g. Overhauling & Periodic upkeep.

Predictive maintenance Equipment Condition evaluated periodically and maintenance carried out.

OBJECTIVES OF TPM
Improve Equipment Effectiveness Achieve Autonomous Plan Maintenance To Train all staff in maintenance skills To Zero Breakdowns

COST TRADE-OFF BETWEEN PM & CM

1000 C o 650 s t i n R u p e e 500 Breakdown Penalty costs (CM)

Total cost of maintenance Maintenance Activity Costs (PM)

50 0 LOW MEDIUM MAINTENANCE HIGH

BIG LOSSES

1. Breakdowns 2. Setup and changeover 3. Idling time and stoppages 4. Reduced speed 5. Defects and reworks

Long interruptions, Costly Repairs Taking Longer time than needed Hard to quantify, add to big losses Equipment cycle time reduces Quality losses & Unhappy customer

BENEFITS
Increased productivity Equipment reliability Reduced down time Increased plant capacity Low production maintenance costs Team work Between Production & Maintenance People Improved safety & Profit

     

THANK YOU