TPM

TOTAL PRODUCTIVE MAINTENANCE

SUBMITTED BY-
SAKSHI SINGH
JAYANT KUMAR
SHUBHAM DHILLAN
 INTRODUCTION TO LEAN
MANUFACTURING
Lean manufacturing is a production philosophy that
focuses on minimizing waste and maximizing efficiency. It
originated in Japan in the automotive industry and has
since been adopted by companies in various industries
around the world.

The main goal of lean manufacturing is to create value for

the customer while reducing costs and lead times. This is
achieved through the implementation of continuous
improvement processes and the elimination of non-
value-added activities.
 1 value
2 value stream
THE FIVE
PRINCIPLES OF 3 flow
LEAN
MANUFACTURING
4
pull
5 perfection
 INTRODUCTION
TPM is a method of maintenance that improves
equipment performance, reduces failures, and
encourages operators to do autonomous
maintenance by integrating the entire
workforce in day-to-day operations.

Strategic approach that brings together

both production and maintenance
activities by combining strong working
behaviors, collaboration, and
continuous improvement.
 OBJECTIVE
Enhancing the Overall Efficiency of the Equipment (OEE)
Enhancing the efficiency and effectiveness of
maintenance
Personnel education and training
Developing equipment to facilitate maintenance
prevention
 LOSSES THAT ONE CAN
PREVENT BY APPLYING TPM
1. Breakdowns
2. Setups and Adjustments
3. Idling
4. Sudden-Short-term
Shortages
5. Defects and Rework
6. Start-up Losses

 8 PILLERS OF TPM
5S FOCUSED IMPROVEMENT

AUTONOMUS MAINTENANCE Education and training

PLANNED MAINTENANCE Safety, health, and environment

QUALITY MAINTENANCE Office TPM

5-s Method in the workplace

 AUTONOMOUS

MAINTENANCE

Description Benefits
Gives operators greater “ownership”

of their equipment.
Places responsibility for Increases operators’ knowledge of

routine maintenance, such their equipment.

as cleaning, lubricating, Ensures equipment is well-cleaned

and inspection, in the and lubricated.

Identifies emergent issues before

hands of operators.
they become failures.
Frees maintenance personnel for

higher-level tasks.
 PLANNED
MAINTENANCE
Benefits
Description
Significantly reduces instances of

unplanned stop time.

Schedules maintenance tasks
Enables most maintenance to be

based on predicted and/or

planned for times when equipment

measured failure rates is not scheduled for production.

Reduces inventory through better

control of wear-prone and failure-

prone parts.
 QUALITY MAINTENANCE

Description Benefits
It aims to identify and
Reduces number of defects.
eliminate the root cause of
Reduces cost by catching

any defects. Therefore, defects early

producing and delivering
quality products to the
end-user.
 FOCUSED IMPROVEMENT
Description Benefits
Recurring problems are

It involves imparting

identified and resolved by

required skills and

cross-functional teams.
knowledge to the

equipment operators. So,

Combines the collective

creating a multi-skilled

talents of a company to

workforce that can

create an engine for

handle and resolve the

issues continuous improvement.

 Training and Education
Description
Fill in knowledge gaps
necessary to achieve TPM
goals. Applies to operators,
maintenance personnel and
managers.
Benefits
Operators develop skills to
routinely maintain equipment and
identify emerging problems
Maintenance personnel learn
techniques for proactive and
preventative maintenance.
Managers are trained on TPM
principles as well as on employee
coaching and development.
Safety, Health, Environment
Description Benefits

Eliminates potential health

Maintain a safe and safety risks, resulting in a
safer workplace.
and healthy
working Specifically targets the goal
environment of an accident-free
workplace
 TPM in OFFICE
Description Benefits

Extends TPM benefits beyond the

Apply TPM techniques plant floor by addressing waste in
administrative functions.
to administrative
functions Supports production through
improved administrative
operations (e.g., order processing,
procurement, and scheduling).
 BENEFITS OF TPM

1. Equipment Availability 2) Costs Reduction

3) Development of Employees 4) Motivated Bunch of Employees

5) Better Quality Control 6) Decreased Mishaps

7) Ensure Pollution Control 8) Better Care of Equipment

 Awareness Organization

Phases of TPM
Implementation Planning

Evaluation Implementation
 OVERALL EQUIPMENT
EFFECTIVENESS (OEE)

It is the performance indicator of the TPM that measures the

equipment’s effectiveness. The implementation of TPM increases the
overall efficiency of the equipment.
OEE CALCULATION EXAMPLE
ADVANTAGES OF OEE
Visualizing Performance

Production Insight

Increase Competitiveness

Reduce Machinery Cost

Return on Investment (ROI)

Thank you!