Total Quality Management

TQM

Total Productive Maintenance

SESSION 13

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Agenda

History
Introduction
Why TPM?
Goals
Planning
Getting Started
Types of Maintenance
TPM Pillars
Benefits of TPM
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TPM - History

TPM is an innovative Japanese

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concept.
Origin of TPM can be traced back to
1951.
Nippondenso of the Toyota Group was
the first company to introduce plant
wide preventive maintenance in 1960.

TPM Introduction

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Total Quality management (TQM) and Total

Productive Maintenance (TPM) are
considered as the key operational activities of
the quality management system.
TPM is keeping the current plant & equipment
at its highest productive level through
cooperation from all areas of the organization.
Breakdown of traditional barrier production
and maintenance personal work together.

TPM Introduction

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One of the main objectives of TPM is to

increase the productivity of plant and
equipment with a modest investment in
maintenance.
In order for TPM to be effective, the full
support of the total workforce is required.

Why TPM?
1. The major difference between TPM and
other concepts is that the operators are also
made to involve in the maintenance process.
2. Avoid wastage in quickly changing
environment.
3. Reduce Cost of Manufacturing.
4. Produce a low batch quantity at the earliest
possible time.
5. Goods send to Customers must be non
defective

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TPM Goals

The overall goals of TPM are:

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Maintaining and improving equipment capacity.

Maintaining equipment for life.
Using support from all areas of operation.
Encouraging input from all employees.
Using teams for continuous improvement.

Planning

The first activity in any assessment of

performance is to determine the current
operating parameters.
Where are we today?
What systems do we have in place, and how
do they work?
What is the current condition of the plant and
equipment?
Are we starting from scratch, or do we have
workable systems that only need to be
improved?

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Getting Started

TPM is an extension of the TQM philosophy

to the maintenance function.
7 basic steps get an organization started
towards TPM:
1. Management learns the new philosophy.
2. Management promotes the new philosophy.
3. Training is funded and developed for everyone in
the organization.
4. Areas of needed improvement are identified.
5. Performance goals are formulated.
6. A implementation plan is developed.
7. Autonomous work groups are established.

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Types of Maintenance
1. Breakdown Maintenance
2. Preventive Maintenance

Periodic Maintenance
Predictive Maintenance

3. Corrective Maintenance
4. Maintenance Prevention

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TPM Pillars

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Pillar 1: 5S

TPM starts with 5S.

Problems can not be clearly seen when the
workplace is unorganized.
Cleaning and organizing the workplace helps
the team to uncover problems.
Making problems visible is the FIRST STEP of
improvement.
SEIRI
SEITON
SEISO
SEIKETSU
SHITSUKE

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SORTING
ORGANIZE
SHINE THE WORKPLACE
STANDARDIZATION
SELF DISCIPLINE

Pillar 2: JISHU HOZEN

(Autonomous Maintenance)

This pillar is geared towards developing

Operators to be able to take care of small
maintenance tasks, thus freeing up skilled
maintenance people to spend time on more
value added activity and technical repairs.
The operators are responsible for up keep of
their equipment to prevent it from
deteriorating.

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Pillar 3: KOBETSU KAIZEN

KAIZEN means improvement for good. Kobetsu

means focused.
Basically Kobetsu Kaizen is for small adjustments
and corrections but effects the whole process and
carried out on a continual basis and involves all
people in the organization.
The principal behind is that a very large number
of small improvements are more effective in
an organizational environment than a few
improvements of large value.
This pillar is aimed at reducing losses in the work
place that affect our efficiencies.
By using a detailed and through procedure, we
eliminate losses in a systematic method using
various Kaizen Tools.
These activities are not restricted to production
areas and can be implemented in administration
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area as well.

Pillar 4: Planned Maintenance

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It is aimed to have trouble free machines and

equipments producing defect free products
for total customer satisfaction.
With planned maintenance, we evolve an
effort from a reactive to a proactive method
and use trained maintenance staff to help
train the operators to better maintain their
equipment.
Policy:

Achieve and sustain availability of machines

Optimum maintenance cost.
Reduce spares inventory.
Improve reliability and maintainability of machines.

Pillar 5: Quality Maintenance

It is aimed towards customer delight providing

highest quality through defect free
manufacturing.
Focus is on eliminating non-conformances in
a systematic manner.
Quality defects are classified as CUSTOMER
END defects and IN HOUSE defects.
For customer-end data, we have to get data
on Customer-end line rejection and field
complaints. In-house data include data related
to products and data related to process.

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Pillar 6: Training

It is aimed to have multi-skilled revitalized

employees whose moral 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.
The employees should be trained to achieve
the form phase of skill which are as under:

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.
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Pillar 7: Office TPM

Office TPM should be started after activating from

other pillars of TPM (JH, KK, and QM.PM).
Office TPM must be flowed to improve productivity,
efficiency in the administrative function and identify
eliminate losses. This includes analyzing process and
procedure towards increased office automation.
Office TPM covers twelve major losses. These are:
1.
2.

3.
4.
5.
6.
7.
8.
9.
10.
11.
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12.

Processing loss
Cost loss including in areas such as procurement, accounts
marketing leading to high inventories.
Communication loss.
Idle loss.
Set-up loss.
Accuracy loss
Office equipment breakdown.
Communication channel breakdown.
Time spent on retrieval of information.
Non availability of correct on line stock status.
Customer complaints due to logistics.
Expense on emergency dispatches/purchases.

Pillar 8: Safety & Environmental

Management

Assuring safety and preventing adverse

environmental impacts are important priorities
in any TPM effort.
Safe and healthy working environment
improves the overall efficiency of all the
processes.

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Benefits of TPM

Direct Benefits of TPM

1. Increase Productivity and
Overall Plant Efficiency by 1.5
to 2 times
2. Rectify customers complaints
3. Reduce manufacturing cost
by .percent
4. Satisfy the customers needs
by 100%
5. Reduce accidents
6. Comply with all relevant
governmental regulations
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Indirect Benefits of TPM

1. Higher confidence level
among the workers
2. Keep the work place clean,
neat and attractive
3. Favourable change in the
attitude of the operators
4. Achieve goals by working as
Team
5. Share knowledge and
experience
6. The worker get a feeling of
OWNING the machine

Example Problem

Refer the example problem discussed in the

topic Improvement Needs available in the
book.

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THE END

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