TPM PROACTIVE TOOL FOR PREVENTION OF ABNORMALITIES INTRODUCTION

Total concept of TPM was introduce in Japanese automobile industry and is now part of corporate culture of leading Japanese industries like Toyota , Nissan and their suppliers .TPM is now also applied In other industries microelectronics , consumer appliances , plastics, chemical and petrochemicals.

What is TPM?
TPM was originally defined by the Japan Institute of Plant Maintenance ( JIPM ) as approach to Maximize the overall equipment effectiveness Establish a comprehensive predictive maintenance ( pm ) system covering the life of equipment Involve all department that plant ,use and maintain equipment Involve all employees from top management to front line workmen Promote predictive maintenance ( pm ) through motivation management

What does the TPM look for?

A. Aim at improvement of condition through improvement of employees and equipment B. Aim in developing competent Equipment operator Capable of performing autonomous maintenance effectively Maintenance engineer Capable of carrying out planned maintenance activities to reduce the mean time to repair ( MTTR ) & prolong the measuring between two failures ( MTBF ) and Design engineer Capable of planning maintenance free equipment and use friendly so as to reduce the life cycle cost ( LCC ) through training of concerned personnel C. Aim at improvement of equipment capabilities through improvement in overall equipment efficiency (OEE ),life cycle cost ( LCC ),and vertical start up D. Aim at improvement of the corporate condition

EFFECTS OF TPM

SR NO
1 2 3 4 5 6 7 8 9 10

AREA OF TPM EFFECT

Productivity Quality Cost Delivery Safety Motivation Self maintenance Confidence Clean environment Improved the image

EFFECTS OF TPM
Productivity improvement Reduction in number of sporadic failures Reduction in product defects Reduction in customer claim Reduction in maintenance cost Reduction in product inventories Reduction in accident Elimination of pollution Increase in number of employee suggestion Operator to take care of machine themselves Zero break down and zero defects operator get new confidence I their own abilities Work place used to be clean and pleasant Company image improve so possibility of increase in orders

ABNORMALITY TAGS CLASSIFICATION

SR NO
1

ABNORMALITY
Minor flow contamination damage play slackness Abnormal phenomena adhesion Unfulfilled basic condition lubrication Lubricant supply Oil level gauges Tightening Inaccessible place Cleaning Checking Lubricating Tightening Operation Adjustment Contamination source Product Raw material Lubricant Gases Liquids Scrap Quality defect sources Foreign matter Shock Moisture Grain size Concentration Viscosity

EXAMPLE
Dust, dirt, powder, oil, grease, rust, paint Cracking, crushing, deformation, chipping, bending Shaking, falling out, tilting, eccentricity, wear, distortion, corrosion Belts, chains Unusual noise, overheating, vibration, strange smell, discolouration Blocking, hardening, accumulation of debris, peeling, malfunction

Insufficient ,dirty, unidentified, unsuitable or leaking lubricants Dirty, damaged or deformed lubricants inlet Dirty, damaged, leaking, no indication of correct level Nuts and bolts slackness, missing, cross threaded too long, crushed Machine construction, covers, layout, footholds space Covers, construction, layout, instrument position and orientation Position of lubricant inlet, construction, height footholds, lubricants outlet Covers, construction, layout, size, footholds Machine layout, position of valves, switches and lever and foothold Position of pressure gauge, thermometer, flow meter, moisture gauge

Leaks, spills, spurts, scatter, out flow Leaks, spills, spurts, scatter, out flow Leaking, split and seeping lubricant oil, hydraulic fluid, fuel oil Leaking compressed air, gases, steam vapour, exhaust, fumes Leaking, splits and spurting cold water, half finished products Flashes, cuttings, packaging materials and non-conforming products

Inclusion, infiltration and entrainment of rust, chips, wire scraps Dropping, jolting, collision, vibration Too much, too little, infiltration, defective elimination Abnormalities in screens, centrifuge separators, compressed air separators, etc. Inadequate warming, heating, compounding, mixing, evaporation Inadequate warming, heating, compounding, mixing, evaporation

Unnecessary and non-urgent items Machinery Piping equipment Measuring instruments Electric equipment Jigs and tools Spare parts Unsafe places floors Steps Lights Rotating machine Lifting gear

Pumps, fans, compressor, columns, tanks Pipes, hoses, ducts, valves, damper Temperature, pressure gauges, vacuum gauges, ammeters, etc. Wiring, piping, power leads, switches, plugs General tools, cutting tools, jigs, moulds, dies, frames Standby equipments, spares, permanent stocks, auxiliary materials Unevenness, ramps cracking, peeling, wear Tool steep, irregular peeling, anti sleep covering corrosion Dim, out of position, dirty or broken covers not properly, explosion proofed Displaced, fallen off or broken covers, no safety of emergency stop devices Wires, hooks, brakes and other parts or cranes and hoists

TPM DEVELOPMENT PROGRAM STEPS

Tpm development program steps

preparation

introduction

implementation

stabilization

Four Steps Of TPM Development Program

STEP 1 PREPARATION
Establish common language To build management will the top management visit other units where TPM activities have progressed Launching housekeeping recovery program through zone and teams covering all the employees Introduce WCM awareness programs

STEP 2 INTRODUCTION
Once the master plan has been agreed upon by the organization the stage is set for kick off of the activities TPM kick off is starting point of application of TPM . it is a wide meeting in which client companies, affiliates and sub contractors are invited. Master plan , policies , goals and reports of activities during the preparation stage are presented in the meeting The kick off function is for company wide publicity and raising the morale of the employee

STEP 3 IMPLEMENT
In this stage 8 activities are carried which are called eight pillars in the development of TPM activity: 4 Activities are for establishing the system for production efficiency Autonomous Maintenance Focussed improvement Planned maintenance Development management 1 Activity for initial control system of new products and equipment "Quality Maintenance" 1 Activity for improving the efficiency of administration "Office TPM " 1 Activity for Training & Development 1 Activity for control of safety, sanitation as working environment

1. Autonomous maintenance
Autonomous maintenance is the process by which equipment operators accept and share responsibility (with maintenance) for the performance and health of their equipment

Autonomous Maintenance skills to be Ability to discover abnormalities. Ability to correct abnormalities and restore equipment functioning. Ability to set optimal equipment conditions. Ability to maintain optimal conditions. The specific goals of Autonomous Maintenance include the following Prevent equipment deterioration through correct operation and daily inspections. Bring equipment to its ideal state through restoration and proper management. Establish the basic conditions needed to keep equipment well maintained. Four significant elements of the Autonomous Maintenance effort are discussed in further detail in this section:

2 focused improvement
Focused improvement includes all activities that maximize the overall effectiveness of equipment, processes, and plants through uncompromising elimination of losses and improvement of performance Overall Equipment Effectiveness (OEE) is the key metric of Focused Improvement. The development of a key performance indicator system covering an area down to team / employee level transpires with the basic indicators which is the basis of this evaluation. Q quality C costs D delivery service

 its possible to visualize detailed information about losses and wastes using the structure of the 16 losses. The 3 Main Categories of Losses are: 1. 8 Main Losses due to the Machine 2. 5 Losses due to Human Work 3. 3 Losses due to Processes

planned maintenance
Planned Maintenance is to establish and maintain optimal equipment and process conditions planned maintenance system means raising output (no failures, no defects) and improving the quality of maintenance technicians by increasing plant availability Implementing these activities efficiently can reduce input to maintenance activities and build a fluid integrated system, which includes: Regular preventive maintenance to stop failures (Periodic maintenance, predictive maintenance). Corrective maintenance and daily MP [maintenance prevention] to lower the risk of failure. Breakdown maintenance to restore machines to working order as soon as possible after failure.

4 quality maintenance
Quality maintenance, is establishment of conditions that will preclude the occurrence of defects and control of such conditions to reduce defects to zero Quality Maintenance is achieved by establishing conditions for zero defects, maintaining conditions within specified standards, inspecting and monitoring conditions to eliminate variation, and executing preventive actions in advance of defects or equipment/process failure The precondition for implementation of quality maintenance is to put the equipment, jigs, and tools for ensuring high quality in the manufacturing process, as well as processing conditions, human skills, and working methods, into their desired states The core concept of Quality Maintenance is integrating and executing the structures, practices, and methodologies established within Focused Improvement, Autonomous Maintenance, Planned Maintenance, and Maintenance Prevention.

5 EDUCATION AND TRAINING

It is aimed to have multi-skilled revitalized employees whose morale is high and who has eager to come to work and perform all required functions effectively and independently. Education is given to operators to upgrade their skill It is not sufficient know only Know-How by they should also learn Knowwhy. By experience they gain, Know-How to overcome a problem what to be done. The different phases of skills are 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 Educating and training activities:

1. Setting policies and priorities and checking present status of education and training. 2. Establish of training system for operation and maintenance skill up gradation. 3. Training the employees for upgrading the operation and maintenance skills. 4. Preparation of training calendar. 5. Kick-off of the system for training. 6. Evaluation of activities and study of future approach

6 development management
This refers to the learning process that happens in TPM implementation and during different types of maintenance practices, when a) ease of manufacture, b) policy development of new technologies, c) determination of detailed specifications etc are answered.

 Development of management involves four phases, a) planning b)implementation, c) design d) manufacturing, e) initial phase production. The methodology adopted is for understanding of the present machine structure, incorporate planned maintenance sheetsto eliminate defects, and design validation

7 SAFETY, HEALTH AND ENVIRONMENT Main target of this piller is

Zero accident, Zero health damage Zero fires.

In this area focus is on to create a safe workplace and a surrounding area that is
not damaged by our process or procedures

To create awareness among employees various competitions like safety slogans,

Quiz, Drama, Posters, etc. related to safety can be organized at regular intervals

8 OFFICE TPM
Office TPM must be followed to improve productivity, efficiency in the administrative functions and identify and eliminate losses. This includes analyzing processes and procedures towards increased office automation. Office TPM addresses twelve major losses

 They are 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

STEP 4 STABLIZATION Stabilize the system is necessary for continued return on our efforts Effective team activity are to be monitored effectively through structured periodically bodies by top level management. There are different committees made by organization Introduction to sub committee Steering committee Plant level committee Sub section level committee Kobetsu - kaizen-sub committee Jishu hozen sub committee Planned maintenance sub - committee Initial flow control sub committee Quality maintenance committee Office improvement sub committee Education and training sub committee

Health and safety sub committee