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Total Productive Maintenance

TPM (Total Productive Maintenance) is a Maintenance Philosophy into the manufacturing process. TPM is A Culture A New Attitude

With everyone participating


For the betterment of the company. The Success of TPM requires Total visible commitment Support from the top Continuous Improvement

Total Productive Maintenance


Goals of TPM :Zero Breakdown Zero Defect Zero Accidents

Zero Breakdown Zero Defect Zero Accidents

Total Productive Maintenance


Benefits of TPM (P,Q,C,D,S,M):-

Productivity Increase due to OEE ( Overall Equipment Effectiveness ) improvement. Quality Improvement through Zero Defects. Cost Reduction through process improvement. Delivery Improvement through Breakdown reduction to zero. Safety, Health & Environment Improvement by zero accident and healthy working condition. Morale of the Employees will be improved through involvement and participation in TPM activities.

Total Productive Maintenance


JISHU HOZEN (AUTONOMOUS MAINTENANCE)
- JISHU HOZEN is the first pillar of TPM. -MY MACHINE I MAINTAIN.

- JH is just like daily care of our body (Brushing, Bathing, Cleaning)


-Detect & Sense abnormalities.

JISHU HOZEN STEP 1 7 Types of Abnormalities :1. Minor Flaws 2. Unfulfilled Basic Conditions 3. Hard to CLIT Area 4. Sources of Contamination 5. Unnecessary/Non urgent items 6. Sources of Quality contamination

7. Unsafe places on and around the machine

1. MINOR FLAWS:Contamination - Dust, Dirt, Powder, Oil, Rust, Grease

Damage Cracking , Crushing, Deformation, Bending


Play Distortion, Wear, Shaking Slackness Belts, Chains Abnormal Phenomenon Unusual noise, Overheating, Vibrations, Strange smell, Incorrect pressure or current

Adhesion Malfunction, Accumulation of chips & dust

2. UNFULFILLED BASIC CONDITIONS :-

Lubrication Insufficient, Dirty, Leaking, Unidentified Lubrication Supply Dirty, Damage, Insufficient, Faulty lubricant pipes Oil level gauges Dirty, Damaged, Leaking, No indication of correct level Tightening Nuts and Bolts slackness, Missing, Cross-threaded, Too long, Crushed, Corroded, Unsuitable washers

3. HARD TO CLIT AREA:Cleaning Machine construction , Covers, Layout, Footboards Lubrication Position of lubricant inlet, Construction, Inaccessible lubrication pipes

Inspection Operating range of pressure, Tools, Foundation bolts, Insufficient see through
Tightening Covers, Construction, Fixture Butting points Adjustment Position of pressure gauges, Flow meters , Temp. gauges

4. SOURCES OF CONTAMINATION :-

Compressed Air leakage from joints, cracks, broken pipes Lubricants Leakage, Over filling, Seepage Scrap Chips, Cast iron dust, Used lubricants, reject components Liquids Leaking water, Waste water, Leaking supply lines
Others Contaminants by people such as used clothes, Eatables, Biscuit wrappers

5. UNNECESSARY/NON URGENT ITEMS :Machinery Pumps, Fans, Compressors, Coolant tank Pipes Coolant pipes, Hoses, Valves, Attachments, Brackets Measuring Instruments Temperature & Pressure gauges, Ammeters Electrical equipments Switches, Wires, Plugs, Cables Jigs, Fixtures & Tools General tools, Cutting tools, Jigs, Fixtures Spare Parts Standby equipments, Obsolete materials Makeshift repairs Tape, unused nuts & bolts, metal plates, pipes & rods

6. SOURCES OF QUALITY CONTAMINATION :Foreign Matter Dust, Rust, Chips, Moisture, Paper pieces, Stones, Excess material Shock Dropping, Jolting, Collision, Vibrations Hot Weather Variation in bore size Moisture Compressed air mixed with water Fixture &Tools Low clamping pressure, Worn out locating pins, Jacks not working, Worn out tools Malfunction Sensors, limit switches, pressure regulators Human Error Inadequate butting & resting

7. UNSAFE PLACES ON AND AROUND THE MACHINE :-

Rotating Parts Spindle, Axes, Chips coming out of machine, Sharp corners Electrical Controls Naked wires, Uncovered circuits Floors Unevenness, Damaged, Oily Lights Dim, Out of position, No safety or Emergency stops Cranes Wire rope or chain worn out, Tackle welding broken or damaged Others Over inventory, Hot chips coming out of gaps or open doors

- 7 Steps of JH (Jishu Hozen) :JH0 Understanding equipment & Thorough Cleaning JH- 1 :- Initial Cleaning &Tagging. JH- 2 :- Implementing Countermeasures. JH- 3 :- Developing Tentative Standards for CLIT JH- 4 :- General Equipment Inspection ( Equipment Competent Operator ) JH- 5 :- General Inspection ( Process Competent Operator )

JH- 6 :- Standardization.

JH- 7 :- Autonomous Management

JH0 Understanding equipment & Thorough Cleaning


1. 2. 3. 4. Understand Functions of Equipment And Auxiliaries Identify Failures And Breakdowns 1S-2S on and around the machine Make the list of Hard to Clean Areas Hard to Lubricate Hard to Inspect Hard to Tighten Hard to Adjust 5. Record Cleaning Time 6. Meeting after Daily Activities 7. Arrange for cleaning aids. 8. Preparation of Abnormality Matrix.

JH-01:- Initial Cleaning and Tagging


1. White and Red tagging to be done for initial cleaning and non conformities as per machine maintenance manual

2. Cleaning to be done with purpose of identifying abnormalities


3. Preparation of guidelines for cleaning 4. Preparation of One Point Lesson (OPLs)

5. Four Step audit

JH- 2 :- Implementing Countermeasures.


1.

White and Red tagging done for countermeasures developed against a source of contamination, hard to access area for cleaning, lubricating, Inspection, tighten and adjust.

2. Find out the areas for hard to CLIT 3. Gemba Kaizens

4. Four Step audit

JH- 3 :- Developing Tentative Standards

for CLIT
1.

Preparation of Tentative Standards.

2. Create visuals on machine 3. One Point lesson (OPLs) 4. Four Step audit

JH- 4 :- General Equipment Inspection

( Equipment Competent Operator )


1. Basic knowledge on Nuts, Bolts and Screws. 2. Knowledge on various types of Pumps, Motors, Belts, Bearings, Couplings, Hydraulic Units and Lubrication Units. 3. Knowledge of Electrical switches, Limit Switches, Sensors, Pressure Switches.

4. By acquiring this knowledge the operators are well aware of machine parts.
5. Various parts of the machine, their functioning and troubleshooting.

6. Four Step Audit

JH- 5 :- Autonomous Inspection)

( Process Competent Operator )


1. Make Autonomous Inspection work efficient to assure correct maintenance and management of Jishu Hozen standards and to accomplish visual control and prevention of careless errors. 2. Re-examine the cleaning, Lubrication and Inspection standards and prepare Jishu Hozen standards.

3. Re-examine for zero breakdown and zero defects.


4. New methods of Cleaning and Inspection are used. 5. Inspection that is made in Preventive Maintenance is included in JH.

JH- 6 :- Standardisation

1. Kaizen and building mechanism for maintenance and management of autonomous inspection. 2. Eliminate Quality troubles and defects to expand activities to periphery of equipment. 3. Everybody should follow the work instructions strictly. 4. Necessary spares for equipments is planned and procured by maintenance.

JH- 7 :- Autonomous Management


1. OEE and other TPM Targets must be achieved by continuous Improvement through Kaizens.

2. PDCA (Plan, Do, Check and Act ) cycle must be implemented for Kaizens.

One Point Lesson


Tool to convey information regarding knowledge and skill of equipment, and about trouble/improvement cases. Designed to help enhance knowledge and skill in a short period of time at just the right time whenever required. To upgrade the level of expertise of whole circle. To encourage every member to think, study and prepare OPL and teach to all the team members.

One Point Lesson

One Point Lesson

One Point Lesson

One Point Lesson

One Point Lesson

One Point Lesson

One Point Lesson

One Point Lesson

One Point Lesson

One Point Lesson

One Point Lesson