A PAPER ON

TOTAL PRODUCTIVE MAINTENANCE
BY
AJAY KUMAR (Final T.C.) niekee4@gmail.com 9860043028 & KANCHAN KUAMR (Final T.P.E.) kanchantpe07@gmail.com 09921519684

D.K.T.E.S. Textile & Engineering Institute Rajwada, Ichalkaranji

In this paper we will see that Total Productive Maintenance (TPM) challenges the view that maintenance is no more than a function that operates in the background and only appears when needed . for instance. but also to extend and optimize their overall performance. . not simply to keep machines running smoothly. The objective of TPM is to engender a sense of joint responsibility between supervision. In today¶s highly competitive market. just in-time (JIT) and total quality-management (TQM) techniques has given rise to what has been called the total productive-maintenance (TPM) approach. operators and maintenance workers. cost effectiveness of an enterprise is plays vital role in manufacturing process. where maintenance activities are key to the smooth running of the textile mill. The requirement for optimal preventive maintenance using.ABSTRACT: Today¶s world is one of growing expectations. Textile industry is the second largest industry in the world next to agriculture. increasingly onerous regulatory constraints. Total Productive Maintenance (TPM) is also a cost reduction tool used in industry particularly in textile mills. shifting technological paradigms and apparently endless and urgent reorganizations.

TPM is a innovative Japanese concept. The origin of TPM can be traced back to 1951 when preventive maintenance was introduced in Japan. maintenance became a problem as more maintenance personnel were required. and improve all capital assets of a company. with the change in market conditions and customer requirements time to time. Implementing it throughout a plant correctly will take several years. It is about getting the most overall benefit from your equipment over the life of the equipment. This lead to maintenance prevention. operators produced goods using machines and the maintenance group was dedicated with work of maintaining those machines. Thus preventive maintenance along with Maintenance prevention and Maintainability Improvement gave birth to Productive maintenance.TPM is not just about ³maintenance´. So the management decided that the routine maintenance of equipment would be carried out by the operators which is also called as Autonomous maintenance.INTRODUCTION The philosophy of Productive maintenance is evolved. However the concept of preventive maintenance was taken from USA. By then Nippondenso had made quality circles. involving the employees participation. The maintenance crew went in the equipment modification for improving reliability. Thus Nippondenso which already followed preventive maintenance also added Autonomous maintenance done by production operators. Preventive maintenance is the concept wherein.TPM will not be an overnight success. . The modifications were made or incorporated in new equipment. monitor. Thus all employees took part in implementing Productive maintenance. The aim of productive maintenance was to maximize plant and equipment effectiveness to achieve optimum life cycle cost of production equipment. For production it is a system that maximizes equipment effectiveness and maintains product flow. Nippondenso was the first company to introduce plant wide preventive maintenance in 1960. one of the features of TPM . TPM is a company-wide system developed to maintain. however with the automation of Nippondenso. Based on these developments Nippondenso was awarded the distinguished plant prize for developing and implementing TPM. Maintenance group took up only essential maintenance works.

WHY TPM? TPM was introduced to achieve the following objectives. It requires commitment to the programme by members of the upper level management team as well as empowering employees to initiate corrective actions for defaulting aspects of the system or process under their jurisdiction. Reduce cost. y y y y Avoid waste in a quickly changing economic environment. as an integral part of the manufacturing process. WHAT IS TPM? A process which involves people from factory/office working together safely. in small organized teams. Thus Nippondenso of the Toyota group became the first company to obtain the TPM certification. Down time for maintenance is scheduled as a part of the manufacturing day and. It can be considered as the medical science of machines. TPM brings maintenance into focus as a necessary and vitally important part of the business.to ensure and environment possible. This recently-introduced maintenance strategy for plant and equipment usually involves a change in the mind-set of personnel towards their job responsibilities. The goal is to hold emergency and unscheduled maintenance to a minimum. Producing goods without reducing product quality. It is no longer regarded as a non-profit activity. . Produce a low batch quantity at the earliest possible time.by the Japanese Institute of Plant Engineers ( JIPE ). Total Productive Maintenance (TPM) is a maintenance program which involves a newly defined concept for maintaining plants and equipment. The important ones are listed below. in some cases.

The use of voluntary small group activities for identifying the cause of failure. Involve equipment operators in the simple. Improving productivity by highly motivated workers. Basic Foundations of TPM  Everyday Maintenance  Periodic Maintenance  Instant Maintenance  Corrective Maintenance  Preventative Maintenance  Predictive maintenance  Pro-active maintenance  Autonomous Maintenance  Reliability Centered Maintenance Motives of TPM 1.y y Goods send to the customers must be non defective. 2. day-to-day basics of equipment cleanliness and checks to enhance employee ownership in maintaining and identifying equipment problems immediately. 3. possible plant and equipment modifications. . which is achieved by job enlargement. Adoption of life cycle approach for improving the overall performance of production equipment.

Reduce the manufacturing cost by 30%. Uniqueness of TPM The major difference between TPM and other concepts is that the operators are also made to involve in the maintenance process. so that there are no customer complaints. You (Maintenance department ) fix" is not followed.  Reduce accidents.  Reduce the manufacturing cost by 30%. The concept of "I (Production operators)Operate. Increase the suggestions by 3 times. . Maintain a accident free environment. Achieve 100% success in delivering the goods as required by the customer.5 or 2 times.TPM Targets: Obtain Minimum 90% OEE ( Overall Equipment Effectiveness ) Run the machines even during lunch. Develop Multi-skilled and flexible workers. BENEFITS OF TPM For the company  Higher Overall Equipment Effectiveness  Less ³firefighting´ to repair machines  Lower operating costs  Better able to meet commitments to customers  Improved ability to compete in the world marketpla  Increase productivity and OPE ( Overall Plant Efficiency ) by 1. ( Lunch is for operators and not for machines ! ) Operate in a manner.

and our future´ . you fix´ ³I fix. you design´ ³I design. For employees  Less pressure on maintenance for urgent repairs  Less pressure on production to recover from breakdown losses  Better cooperation between maintenance. you fix´ ³I fix. you operate´ ³I operate. you design´ ´ TPM Attitude ³We are all responsible for our equipment. our plant. production. and other departments  Reduced chance of accidents  Higher job satisfaction  Improved job security TPM IS A PARADIGM SHIFT Old Attitude ³I operate. Follow pollution control measures  Rectify customer complaints.

Rate of quality output (Defects and rework) TOTAL CALENDER TIME Scheduled Downtime Set-up Time SCHEDULED PRODUCTION TIME Available Operating Time Availability Unplanned Reported Stoppages Actual Operating Time . the OEE is converted to costs using Target Costing Management (TCM) where all the manufacturing measurements are merged with the manufacturing costs to enable costs and manufacturing indices to be translated easily. Thus OEE is a function of the three factors mentioned below. 1. design capacity) 3. tool change.) 2.MEASURE OF TPM TPM success measurement . Availability or uptime (downtime: planned and unplanned. job change etc. It incorporates three basic indicators of equipment performance and reliability. or OEE. Performance efficiency (actual vs.A set of performance metrics which is considered to fit well in a TPM environment is overall equipment effectiveness. this allows management to drive all improvements using cost drivers. For advanced TPM world class practitioners. tool service.

Analyze the causes (but focus your efforts ) 3. 2. Develop solutions & create an improvement plan 4.Speed.Idling and minor stoppages. Measure the extent of the 6 big losses Breakdowns :-Setups and adjustment .Quality defects and rework.Start-up (loss of yield). Set targets and estimate the benefits to OEE .Minor Unrecorded Stoppages Reduced Speed Rejects and Rework Actual Production Time Throughput Rate Full Rate Production Time In-Quality Production Time Quality Rate OEE = Availability x Throughput Rate x Quality Rate Causes of OEE Improving OEE 1.

Repeat as necessary Steps in introduction of TPM in a organization : Step A .5.Establishing the TPM working system and target : Now each area is benchmarked and fix up a target for achievement. as part of it. commitment and active involvement of the top management in needed for this step.. Suppliers as they should know that we want quality supply from them. STAGE C . Related companies and affiliated companies who can be our customers. Take people who matters to places where TPM already successfully implemented. When committees are set up it should take care of all those needs and involve people from Maintenance.Announcement by Management to all about TPM introduction in the organization : Proper understanding. autonomous maintenance. Production. STEP 4 . quality maintenance etc. sisters concerns etc. Quality and Engineering. STEP B . Carry out the plan 6. Senior management should have an awareness program. Some may learn from us and some can help us and customers will get the communication from us that we care for quality output.Initial education and propaganda for TPM : Training is to be done based on the need.IMPLEMENTATION .PREPARATORY STAGE : STEP 1 . Achieving PM award is the proof of reaching a satisfactory level.Setting up TPM and departmental committees : TPM includes improvement. Some need intensive training and some just an awareness. STEP 3 .A master plan for institutionalizing : Next step is implementation leading to institutionalizing wherein TPM becomes an organizational culture. STEP 5 . STEP 2 . Establish measurements to monitor results 7. after which announcement is made to all.INTRODUCTION STAGE This is a ceremony and we should invite all.

sanitation as working environment. one for initial control system of new products and equipment. one for improving the efficiency of administration and are for control of safety. Of these four activities are for establishing the system for production efficiency. Organization Structure for TPM Implementation : Pillars of TPM .In this stage eight activities are carried which are called eight pillars in the development of TPM activity.INSTITUTIONALISING STAGE By all there activities one would has reached maturity stage. Also think of challenging level to which you can take this movement. STAGE D . Now is the time for applying for PM award.

Operative in each department must be trained. Transition is from reactive to proactive (Quality Control to Quality Assurance). 2. It is said that Kaizen has been one of the key ingredients in Japan¶s competitive success in the world market. 5. Autonomous maintenance consists of cleaning. lubrication. much like Focused Improvement. Education and training .A planned maintenance schedule should be planned for timely replacement of components which is must for the effective operation of equipment and long life. which believes that individuals should be responsible for their own equipment and have to perform autonomous maintenance. in such a way that they . components like card wires. Autonomous Maintenance .The pillars over which the TPM implementation is developed are: 1. Kaizen . retightening and inspection. Focus is on eliminating non-conformances in a systematic manner. incremental and constant improvement in process by involving everyone in an organization. Planned Maintenance .Education and training are investments in people that yield multiple returns. This has to be followed by the maintenance team. 4. 3. In spinning mills.It is aimed towards customer delight through highest quality through defect free manufacturing. Quality Maintenance .Gradual. top roller cots require timely grinding and buffing respectively to keep them in good condition for the production of good quality slivers and yarns. It is a continuous program to improve quality and increase productivity.Autonomous maintenance is one of the unique features of TPM.

This includes analyzing processes and procedures towards increased office automation. ability to do improvements. The target of SHE is Zero accident. Japanese Term Seiri Seiton Seiso Seiketsu Shitsuke English Translation Organization Tidiness Cleaning Standardization Discipline Equivalent 'S' term Sort Systematize Sweep Standardize Self ± Discipline . early detection of abnormalities. 7. Safety.must improve the understanding about functions of their machines. Health and Environment (SHE) . Zero health damage and Zero fire. 6. on machines operated by them.In this area focus is on to create a safe workplace and a surrounding area that is not damaged by our process or procedures. Office TPM .Office TPM must be followed to improve productivity. efficiency in the administrative functions and identify and eliminate losses. This pillar will play an active role in each of the other pillars on a regular basis.

Following are the other difficulties faced in TPM implementation. . The time taken depends on the size of the organization. ‡ Many people treat it just another ³Program of the month ´ without paying any focus and also doubt about the effectiveness. This is contradictory to the traditional management improvement strategies.The People of Successful TPM Difficulties faced in TPM implementation: One of the difficulties in implementing TPM as a methodology is that it takes a considerable number of years. ‡ Typically people show strong resistance to change. There is no quick way for implementing TPM.

money.‡ Not sufficient resources (people. etc. time.) and assistance provided ‡ Insufficient understanding of the methodology and philosophy by middle management ‡ TPM is not a ³quick fix ´ approach. . it involve cultural change to the ways we do things ‡ Departmental barrier existing within Business Unit ‡ Many people considered TPM activities as additional work/threat.

One of the most important advantages of TPM is the improvement in the Leadership environment. TPM be the only thing that stands between success and total failure for some companies. Most manufacturing industries are fighting a war to survive! In to-days highly competitive economy. business must face the challenge of continually improving the quality of the goods or services. . TPM may be the only thing that stands between success and total failure for some companies Today. It can be considered as the medical science of machines. with competition in industry at an all time high. the product and the company. Total productive-maintenance (TPM) is a proven and successful procedure for introducing maintenance considerations into organizational activities.Conclusion:. The level of satisfaction and morale among the personnel raises and a feeling of ³ownership´ develop towards the equipment.

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