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TOTAL PRODUCTIVE MAINTENANCE AND TOTAL QUALITY MANAGEMENT

UNIT

Contents

Hours

Overview of TPM

Introduction Background of TPM- Jaanese movement terotechnology logistics comparative analysis of TPM, terotechnology and logistics - Defination of TPM Features of TPM Working of TPM Benefits of TPM Introduction - stages and Steps of TPM Stage A - Preparation stage announcement by management initial Education and propaganda Setting up of TPM and departmental Committee- Model TPM - Establishing TPM working system master plan for institutionalizing Stage B- initial implementation stage- starting TPM or- kick off -Stage C- full implementation or full development stage establishing system for improving production efficiency - Individual Improvement Autonomous Maintenance Planned Maintenance operation and maintenance skill upgradtion training - Establishing initial control system for new products and equipments- establishing quality maintenance organization (Hinshitsu Hozen )- Establishing systems to improve efficiency of administration - Establishing system to control safety and working environment Maturity stage getting the PM award. 12 II Aspects of TPM

Equipment effectiveness and types of losses suspension loss- plant maintenance loss production adjustment loss - Downtime loss equipment failure loss- process failure loss Speed loss-regular production loss-irregular production loss- Defect Loss- Process defect loss loss which caused by rework- Understanding the production system to reduce or eliminate losses- definition - processoperation- Calculating overall Equipment Effectiveness (OEE) TPM Principles and Zero failuresEstablishing basic condition-Keep operating records good prevent equipment from deteriorationImprove weak points in design-Improve skills-set up and adjustment time loss reduction -Internal and external changes. 12 III Autonomous Maintenance

Concept of jishu hozen (autonomous maintenance) steps- intial cleanup preventive measures prepation of maintenance standards creating achievement motivation general inspection Preparing autonomous standards for TPM autonomous inspection standardization - autonomous management

check points for Jishu Hozen institutionalize Jishu Hozen - why why analysis Cause and effect diagram ten kinds of human errors different kinds of defects 12 IV Kaizen Activities

Kaizen activities kaizen programme for future losses Team approach- Mode of failure, collection and analysis of data Sporadic and regular failures- reasons for machine deterioration design inadequaciesConsolidating the maintenance standards role of production department Maintenance manual for periodical maintenance role of maintenance department Efficiency of maintenance Predictive maintenance department- kaizen programme to improve minor stoppage loss study of design parametners Poka yoke Kbestu kaizen ( focus improvement implementation of Kbestu kaizen identifying improvement of equipmet formation of team - defining the contributory problem and collection of data categorise loss plan for completion of project step by step analysis budget support holding the gain Hinhitsu Hozen ( quality improvement - - quality maintenance with aim to produce zero defect relationship of quality maintenance with the eight pillars of TPM five principles of TPM 12 V Implementation of Quality Maintenance

Seven steps implementation of quality maintenance - zero break down and zero defect understanding the present situation bringing things to normalcy - need for system approach analysis of chronic problems PM analysis removal of causes for the chronic problems defining the factors for zero defects Enforcing controlling- improving for attaining zero defect - method for PM analysis defining the problem physical analysis abnormality occurrences relevance of 4M check up investigating methods find out faults chalk out improvement plan - zero accident through TPM safety from TPM point of view reasons for accident - prevention accident using TPM-relationship between initial cleaning and autonomous maintenance -safety implementation points -tools for safety promotion- activity board- one point lesson meeting-relationship between TPM activity and safetyTPM in service area- Focused improvement 12

Text Book: 1. Total Productive Maintanace by K. Ganapathy . V.Narayana, B.Subramaniam and D.K. Srivarsa published quality circle forum of India October 2004