Total Productive Maintenance

Multi Environment Solutions

Aims of TPM

To maximize the production system To organize a practical shop-floor system Zero accidents Zero defects Zero breakdown To involve all the functions of an organization To involve every employee To achieve Zero loss

The Pillars of TPM

Focused improvement Autonomous maintenance Plant- Maintenance Office Maintenance Product Design and Equipment Initial Control Quality Maintenance Workers Education & Training Safety, Hygiene & Environment Control.

TPM Goals

Achieve zero breakdowns & zero losses thru

- Focused Improvement, - Effective Equipment Management Techniques - Autonomous Maintenance Systems.

Cont.

TPM Goals

Prevent losses before they occur thru

- Integrated functions of production - Maintenance - Technical - Commercial - Administration - Finance - Marketing. Cont.

TPM Goals
Achieving zero defects, to - become a consistent supplier of quality products and services - conform customer specifications.

Cont.

TPM Goals

Give effective training to develop highly skilled, motivated and self-reliant workforce.
Prolong life span of equipment by maintainability improvement.
Cont.

TPM Goals

Involve all the members of the team to develop an atmosphere that is - congenial - friendly - energetic which is resulting in pride of job performed with a feeling of ownership of the asset.
Cont.

TPM Goals

TPM ensures environment that is

Clean Accident free Pollution free

working

Cont.

TPM Organization

TPM promotion committees: Company TPM Promotion Committee Plant Promotion Committee Subcommittee of Kaizen Sub-committee of Autonomous Maintenance Sub-committee of planned maintenance Sub-committee of initial flow control Sub-committee of Quality Maintenance Sub Committee of office improvement Education and training committee Safety and Hygiene Committee

Role of TPM Promotion Committee

- Basic policy and Target Setting - Audit of the promotion progress and the education and cultivation of Implementation plan. - Approval of implementation plan Workout remedial measures against problems encountered during promotion of the activities. - Organize the project teams.

Role of the Plant Promotion Committee

- Workout the plan to promote JishuHozen and Kobetsu-Kaizen and check the progress of promotion activities. - Review problems and give instructions to small groups - Organize Kobetsu-Kaizen project teams.

Role of the Subcommittee of Kaizen

Instruct on how to practice Kobetsu-Kaizen - Instruct on how to horizontally replicate TPM. - Analysis of improvement activities Quantitative and Qualitative - Standardization and information exchange.

Role of the Company TPM Promotion Committee

Study how to proceed with the autonomous maintenance step by step Development. - To conduct Audit after completion of each step for assessing progress & guidance for subsequent work.

Role of the Subcommittee of planned maintenance

- Study how to advance the phase development. Instruct how to advance KobetsuKaizen. Instruct how to horizontally replicate TPM Standardization of various items and information exchange

Role of the Subcommittee of initial flow control

- Study cases - Review existing system - Standardize various items - To optimize life cycle cost, as well to improve equipment reliability by Maintenance prevention design.

Role of the Subcommittee of Quality Maintenance

- Study of Himanshitu techniques Instruct how to advance Himanshitu-Hozen - Instruct how to horizontally replicate TPM - Standardization of various items and information exchange

Role of the Sub Committee of office improvement

- Study how to advance the step development - Instruct how to advance KobetsuKaizen - Instruct how to horizontally replicate TPM - Standardization of various items and information exchange

Role of the Education and training committee

- Work out the training plan
- Check the promotion progress and review problem

Role of the Safety and Hygiene Committee

- Educating Safety and Hygiene systems - Control of safety and Hygienic condition

TPM Implementation Steps

Building Management will Establishing common TPM Language Announcement by top Management Introductory Education and campaign Work Environment the 5S Establishing TPM promotion organization and setting up model equipment. Setting basic policy and Target for TPM Creation of Master Action Plan TPM kick off
Cont..

TPM Implementation Steps

Establishing systems for improving production efficiency a. Problem Solving Tools Training on Tools Continuous application of tools b. Waste Elimination c. Kaizen d. Autonomous Maintenance e. Planned Maintenance f. Education and Training
Cont..

TPM Implementation Steps

MP Design and equipment initial

control Quality maintenance Office TPM Safety, hygiene and pollution control Measuring and Monitoring Visual Management Preparation for PM excellence award by JIPM JIPM Final Assessment for PM excellence award.

Major Losses
Shutdown Losses Production Losses Equipment failure Losses Process failure Losses Normal Production Losses Abnormal Production Losses Quality Defect Losses Reprocessing Losses Management Losses Motion Losses Line Organization Losses
Cont.

Major Losses
- Losses resulting from lack of automated system - Measurement Losses - Yield Losses - Energy Losses - Die, Jigs and tools Losses

The common functions of all the Pillars

- Objectives of TPM - Goals of TPM - Implementation Plan for TPM - Loss Structure - TPM Promotion Committees
Minutes of meeting of Promotion Committees/Action Plan TPM

- Processes/Sub-Processes TPM Audits

Focused Improvement
includes all activities that maximize the overall effectiveness of equipment, processes and plant through elimination of losses and improvement of performance. The overall Plant effective (OPE) is calculated as follows: OPE= Availability of Plant x Performance Rate x Quality Rate

Focused improvement
-

Implementation Steps Registration of Improvement Topic Improvement Targets Implementation Plan for the Topic Results of Improvement
Focused Improvement Audit

Autonomous maintenance
This emphasizes the need for individual workers to carry out routine inspection, oiling, repairs, detection of abnormalities of their own equipments for the purpose of Protecting their own equipment.

Autonomous maintenance
Implementation Steps Autonomous Activities Autonomous Maintenance Tags Autonomous Maintenance Standards One Point Lessons Equipment Evaluation Criteria Equipments for Autonomous Maintenance Abnormalities and Counter measures Visual Controls Cont..

Autonomous maintenance
Analysis of MTBF (From Plant Maintenance Module) - Autonomous Audit Maintenance

Plant Maintenance
- Implementation Steps - Equipment Data Base, Specifications and Configuration - Maintenance Activities, Spares Required, Procedure, Safety Precautions - Break Down Maintenance - Planned (Time Based Maintenance) - Opportunity Maintenance - Lubrication Schedule - Inspection Schedule - Calibration of Instruments
Cont..

Plant Maintenance
- Shut Down Maintenance
- Reading of various equipments (Condition Based Maintenance) Resources required/consumed for Maintenance - History of Maintenance/Log Books - Budget Vs. Actual cost of Maintenance - Planned Maintenance Audit

Office Maintenance
Office Functions File/Document Analyzing Forms Office Function work Method Daily Work Survey Work Allocation Daily/Monthly work summary Monthly load Chart

Product Design and Equipment Initial Control

Aims Product Information Points Life Cycle Cost Product Design Information Sheet

Quality Maintenance
-

Quality Maintenance Aims Quality Defect Factors Steps of Quality Maintenance Present Status of Process Process which cause defects Analysis of 4M(Man, Machine, Material and Method) Countermeasures Conditions for 4M that do not produce defects Checking Methods Standards

Quality Maintenance
- Quality Improvement Results - Defect Rate (From Lab Test Module) - Customer Complaint Rate (From Customer Feed Back Module) - Reprocessing Rate (From Production Module) - Quality Variation (From Lab Test Module)

Workers Education & Training

- Training needs - Workers Skills - Training Programs - Training Schedules - Training Infrastructure - Faculty - Training Cost - Feedback - Training Budget/Utilization

Safety, Hygiene & Environment Control

- Accidents - Safety Training, first aid, emergency handling Procedure - Safety Manuals - Health Check up of Employee - Pollution Control Checks and Results - Drinking Water Tests - Safety Audit - Hygiene Audit

Customer Feed Back

- Feed Back Type - Receipt of Customer Feed Back/Complaint - Customer Complaint Response, solution, action - Effect of Complaints