Total Productive Maintainance

& Plant Maintainance

Presented by
Muhammad Waqas Chughtai

©Prepared by Muhammad Waqas Chughtai

 What is Plant & Maintenance?

Plant: Items of physical equipment

which, in order to work, requires the supply
of energy of a kind other than, or in
addition to, the energy supplied by the
exertion of the body of a human or an
animal.
Maintenance: All actions necessary
for retaining an item, or restoring to it, a
serviceable condition, include servicing,
repair, modification, overhaul, inspection
and condition verification

©Prepared by Muhammad Waqas Chughtai

 What is Total Productive
Maintenance ( TPM ) ?
Total Productive Maintenance (TPM) is a
maintenance program which involves a
newly defined concept for maintaining
plants and equipment. The goal of the
TPM program is to markedly increase
production while, at the same time,
increasing employee morale and job
satisfaction.

©Prepared by Muhammad Waqas Chughtai

 Maintenance in Services
Industries
1. Hospital
2. Restaurants
3. Transport companies
4. Banks
5. Hotels and resorts
6. Shopping malls / retail
7. Gas station

©Prepared by Muhammad Waqas Chughtai

 Maintenance in Manufactured
Industries
1. Electronic
2. Automotive
3. Petrochemicals
4. Refinery
5. Furniture
6. Ceramics
7. Food and beverages

©Prepared by Muhammad Waqas Chughtai

 Purpose of Maintenance
1. Prevent breakdown or failures
2. Minimize production loss from failures
3. Increase reliability of the operating systems
4. Goods send to the customers must be non defective.

©Prepared by Muhammad Waqas Chughtai

 Types of Maintenance
1. Breakdown maintenance
It means that people waits until
equipment fails and repair it.

©Prepared by Muhammad Waqas Chughtai

 Continued…

2. Preventive maintenance
It is a daily maintenance ( cleaning, inspection, oiling and re-
tightening ), design to retain the healthy condition of equipment.
2a. Periodic maintenance ( Time Based Maintenance - TBM)
Time based maintenance consists of periodically inspecting,
servicing and cleaning equipment and replacing parts to prevent
sudden failure and process problems.
2b. Predictive maintenance
This is a method in which the service life of important part is
predicted based on inspection or diagnosis, in order to use the
parts to the limit of their service life.

©Prepared by Muhammad Waqas Chughtai

 Continued…
4. Maintenance prevention
It indicates the design of a new equipment.
Weakness of current machines are sufficiently
studied ( on site information leading to failure
prevention, easier maintenance and prevents of
defects, safety and ease of manufacturing ) and
are incorporated before commissioning a new
equipment

©Prepared by Muhammad Waqas Chughtai

 Steps in introduction of TPM
in a Organization
Step A - PREPARATORY STAGE
Step B - INTRODUCTION STAGE
Step C - IMPLEMENTATION
Step D - INSTITUTIONALISING

Next is the detail of each step:

©Prepared by Muhammad Waqas Chughtai

 Step A - PREPARATORY
STAGE
STEP 1 - Announcement by Management to all about TPM introduction in the
organization :
Proper understanding, commitment and active involvement of the top management in
needed for this step. Senior management should have awareness programmes, after
which announcement is made to all. Publish it in the house magazine and put it in the
notice board. Send a letter to all concerned individuals if required.
STEP 2 - Initial education and propaganda for TPM :
Training is to be done based on the need. Some need intensive training and some
just an awareness. Take people who matters to places where TPM already
successfully implemented.
STEP 3 - Setting up TPM and departmental committees :
TPM includes improvement, autonomous maintenance, quality maintenance etc., as
part of it. When committees are set up it should take care of all those needs.
STEP 4 - Establishing the TPM working system and target :
Now each area is benchmarked and fix up a target for achievement.
STEP 5 - A master plan for institutionalizing :
Next step is implementation leading to institutionalizing wherein TPM becomes an
organizational culture. Achieving PM award/ISO certification/etc is the proof of
reaching a satisfactory level.
©Prepared by Muhammad Waqas Chughtai
Organization Structure for
TPM Implementation

©Prepared by Muhammad Waqas Chughtai

 Pillars of TPM

©Prepared by Muhammad Waqas Chughtai

 PILLAR 1 - 5S
TPM starts with 5S. Problems cannot be clearly seen when the work place is
unorganized. Cleaning and organizing the workplace helps the team to uncover
problems. Making problems visible is the first step of improvement.

©Prepared by Muhammad Waqas Chughtai

 Continued… 5S

©Prepared by Muhammad Waqas Chughtai

©Prepared by Muhammad Waqas Chughtai
 SEIRI - Clearing Up

Identification of materials, equipment and

tools data which are necessary or not
necessary, discarding and make space
for the required one’s.

©Prepared by Muhammad Waqas Chughtai

©Prepared by Muhammad Waqas Chughtai
 SEITON - Organizing

• Once Cleaned and then arrange them in orderly

manner.
• People should cultivate the habit of return the
tools to the place from where it was taken.
• Easily accessible
• Reduces time and confusions
• Improves Efficiency

©Prepared by Muhammad Waqas Chughtai

©Prepared by Muhammad Waqas Chughtai
 SEISO - Cleaning

• After Clearing & Organizing

• Organization should Identify
and Eliminate source of Dirt,
Dust, (or) Trash
• Update Constantly

©Prepared by Muhammad Waqas Chughtai

 SEIKITSU- Standardizing

• Not only Job Related but also Personally it is

important.
•Good Working Condition and Personal Hygiene
•Clean Person is conscious of his Work Place
•Good Sanitary Condition
• Job Discipline is the habit of Skill
Development to do work as per Standards.
• Observe Rules & Policies of the Company

©Prepared by Muhammad Waqas Chughtai

©Prepared by Muhammad Waqas Chughtai
SHITSUKE: Training & Development

• Give regular basis training to the

employees about 5s and encourage self
discipline.
Training
©Prepared by Muhammad Waqas Chughtai
 PILLAR 2 - JISHU HOZEN
(Autonomous maintenance)
This pillar works towards developing operators to be able to
take care of small maintenance tasks. The operators are
responsible for taking care of their equipment to prevent it
from deteriorating.

©Prepared by Muhammad Waqas Chughtai

 PILLAR 3 - KAIZEN
Kaizen comes from two Japanese words: Kai
(improvement) and Zen (good). Over time, it became
widely known as “continuous improvement.”
Therefore,
Kaizen is a Japanese business philosophy of
continuous improvement of working practices,
personal efficiency.

©Prepared by Muhammad Waqas Chughtai

 PILLAR 4 - PLANNED
MAINTENANCE
It is aimed to have trouble free
machines and equipments
producing defect free products
for customer satisfaction. This
breaks maintenance down into 3
"families" or groups which was
defined earlier.
1. Breakdown Maintenance
2. Preventive Maintenance
3. Maintenance Prevention
©Prepared by Muhammad Waqas Chughtai
 PILLAR 5 - QUALITY
MAINTENANCE
Quality Maintenance is the sixth pillar of TPM and
aims to assure zero defect conditions. It does this
by understanding and controlling the process
interactions between manpower, material,
machines and methods that could enable defects
to occur.
Quality Maintenance is implemented in two
phases.
The first phase aims to eliminate quality issues.
The second phase ensures that quality is
sustained, by standardizing the parameters and
methods to achieve a zero defect system.

©Prepared by Muhammad Waqas Chughtai

 PILLAR 6 - TRAINING
The aim of the training is to encourage employees/operators to
upgrade their skill.
It is not sufficient know only "Know-How" by they should also learn
"Know-why".
By experience they gain, "Know-How" to overcome a problem what to
be done.
This they do without knowing the root cause of the problem and why
they are doing so. Hence it become necessary to train them on
knowing "Know-why".
The different phase 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.
©Prepared by Muhammad Waqas Chughtai
 PILLAR 7 - OFFICE TPM

Office TPM aims to provide administrative support

to the organization. It has a key function to
eliminate losses from organization’s functions.

©Prepared by Muhammad Waqas Chughtai

 PILLAR 8 - SAFETY, HEALTH
AND ENVIRONMENT
In this area focus is on to create a safe workplace and a surrounding area that
is not damaged by our process or procedures. This pillar will play an active role
in each of the other pillars on a regular basis
Target
• Zero accident,
• Zero health damage
• Zero fires

A committee is constituted for this pillar which comprises representative of

officers as well as workers. The committee is headed by Senior vice President (
Technical ). Utmost importance to Safety is given in the plant. Manager (Safety)
is looking after functions related to safety. To create awareness among
employees various competitions like safety slogans, rehearsal, Posters, etc.
related to safety can be organized at regular intervals.

©Prepared by Muhammad Waqas Chughtai

THANKS

©Prepared by Muhammad Waqas Chughtai