Overview of Total Productive

Maintenance
Source: The Plant Maintenance Resource Center.
http://www.plant-aintenance.com/articles/tpm_intro.shtml

Prepared by
K. Ramanathan
24 October 1 November, 2016
1

1. What is TPM
Total Productive Maintenance (TPM) is based on the
premise that maintenance is a necessary and vitally
important part of business and that it is not a non-profit
activity.
Down time for maintenance is scheduled as a part of the
manufacturing day and, in some cases, as an integral part
of the manufacturing process.
The goal of TPM is to hold emergency and unscheduled
maintenance to a minimum.

2. Types of Maintenance
Breakdown maintenance: Repairs commence only when the equipment fails.
It is relevant when equipment failure does not significantly affect the
operation or production or generate any significant loss other than repair
cost.
Preventive maintenance: This is routine maintenance (cleaning, inspection,
oiling and re-tightening ) that is designed to keep the equipment in good
working condition. Periodic inspection or equipment condition diagnosis
helps to avoid failure through the prevention of deterioration. Equipment
service life can be prolonged through preventive maintenance.
Periodic maintenance (Time based maintenance - TBM): TBM is part of
preventive maintenance and consists of periodically inspecting, servicing and
cleaning equipment and replacing parts to prevent sudden failure and process
problems.

Types of Maintenance (continued)

Predictive maintenance: In this approach, the service life of important
parts of a machine is predicted, based on inspection or diagnosis, so
that the parts may be used to the limit of their service life. Compared
to periodic maintenance, predictive maintenance is condition-based
maintenance. It looks at trend values, measures and analyses data
about deterioration, and employs an on-line surveillance system that is
designed to monitor the condition of the important parts.
Corrective maintenance: This involves retrofitting and/or modifying
equipment and its components so that preventive maintenance can be
carried out reliably. Equipment with design weaknesses are redesigned
to improve reliability and maintainability.
Maintenance prevention: This involves the design of new equipment
based on evidence-based studies of the weaknesses of existing
machines so that the redesigned machines have dramatically lower
failure rates and are easier to maintain.

3. Pillars of TPM

3. Pillars of TPM (continued)

Pillar 1: 5S
Already discussed in Session 1
Pillar 2: JISHU HOZEN (Autonomous Maintenance)
This pillar aims at developing operators so that they can take care of small
maintenance tasks, thus freeing up skilled maintenance staff to spend
time on more value-added activities and complex technical repairs. The
operators are responsible for the upkeep of their equipment to prevent it
from deteriorating.
Pillar 3: Kaizen
"Kai" means change, and "Zen" means good (for the better ). Kaizen refers
to incremental improvements that can be carried out on a continual basis
and involve all people in the organization. The principle behind kaizen is
that a very large number of small improvements, with little or no
investment, can be more effective than trying only for breakthroughs.

3. Pillars of TPM (continued)

Pillar 4: Planned maintenance

Preventive Maintenance
Breakdown Maintenance
Corrective Maintenance
Maintenance Prevention

Pillar 5: Quality maintenance

It is aimed at delighting customers by delivering highest quality through
defect free manufacturing. The focus is on eliminating non-conformances
in a systematic manner through understanding how equipment
performance can affect product quality.
Current quality concerns are first eliminated and potential quality
concerns are addressed.
The emphasis is to move from a reactive to proactive approach (quality
control to quality assurance).

3. Pillars of TPM (continued)

Pillar 6: Training
The aim is to have multi-skilled and motivated employees who can
perform all required functions effectively and independently. Education
and training is given to operators to upgrade their skills both know-how
and know-why. Employees are trained to achieve the four 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.
The goal is to create a factory full of experts

Pillar 7: Office TPM

Office TPM aims at improving productivity and efficiency in administrative
functions so that losses can be eliminated. This includes analysing
processes and procedures and ineffective use of office automation.

3. Pillars of TPM (continued)

Pillar 8: Safety, health, and environment
The focus is on creating a safe workplace and a surrounding
area that is not damaged by other processes or procedures.
This pillar has to be integrated with each of the other pillars.
The objectives are:
Zero accidents
Zero health damage
Zero fires