“the medical science of machines”

What is TPM?

 A company-wide philosophy that is strategically

implemented to maximize Equipment Effectiveness.

The goal is to hold emergency and unscheduled

maintenance to a minimum.
Target:

 Zero accident,

 Zero health damage

 Zero fires.

Create a safe workplace that is not

damaged by our process or procedures.
 The origin of TPM can be traced back to 1951
when preventive maintenance was introduced
in Japan. However the concept of preventive
maintenance was taken from USA.

 Nippondenso was the first company to

introduce plant wide preventive maintenance
in 1960
  Evolution of TPM
Productive
Maintenance

Maintainability
Improvement
Maintenance
Prevention
Autonomous
Maintenance
Preventive
Maintenance
Preventive Maintenance – focus on the care and servicing
by personnel for the purpose of maintaining equipment and
facilities in satisfactory operating condition by providing for
systematic inspection, detection, and correction of
incipient failures either before they occur or before they
develop into major defects.

Autonomous – maintenance is performed by operator or

machine itself.

Maintenance prevention – design of new machine that is

reliable and has lesser probability of breaking down.

Maintainability – the machine can be maintained and

improved on a regular basis
Productive Maintenance – application & sustainability of
Preventive Maintenance,
Autonomous,
Maintenance prevention &
Maintainability .
Pillars of TPM

6S
TPM-BEC
The Zero – Failure Principle
A failure is the tip of the iceberg!

FAILURES

Wear,
leakage, dust, dirt, corrosion,
surface damage, cracking, Expose hidden
overheating, vibration, and noise causes to
prevent quality and
functional failures
before they happen
Hidden causes
 A systematic method for:
- Improving routine inspection and maintenance
- Promoting early detection of abnormal conditions
- Beginning to control chronic losses

 A method that involves production, maintenance, and

engineering

 An approach that:
- Develops operating and maintenance skills
- Strengthens communication and cooperation
- A series of activities implemented in well-defined
developmental steps
Basis in Generating Monthly Preventive
Maintenance Service Schedule:

 Machines with low MTBF

 Machines with high MTTR

 Machines with high maintenance cost

 Machines with long downtime periods

MTBF – Mean Time Between Failure

MTTR – Mean Time To Repair

Total Productive Maintenance Form
Meeting for Productive Maintenance Service
Schedule:
Meeting for Productive Maintenance Service
Schedule:
 Mean Time Between Failure
 is the predicted elapsed time between inherent
failures of a system during operation.
 can be calculated as the arithmetic mean
(average) time between failures of a system.
 Uptime Uptime Uptime

Downtime Downtime Downtime

1/ 3/11 1/ 20/11 1/ 27/11

8:30 AM 10:00 AM 9:00 AM
Time Between Failure Time Between Failure

= 17.06 days or 409.50 hrs. = 6.96 days or 167 hrs.

Mean Time Between Failure (ave.)

= 12.01 days or 288.25 hrs.

• The Higher the MTBF, the Better – it means our machines are reliable
• Target MTBF is 20% improvement from previous month
 Mean Time To Repair
 the time it takes to restore the machine to its
working condition.
 can be calculated as the arithmetic mean
(average) time between repairs.
 Uptime Uptime Uptime

Repair Repair Repair

30 mins. 25 mins. 40 mins.

Mean Time To Repair (ave.)

= (30+25+40) / 3
= 31.67 mins.

• The Lower the MTTR, the Better – it means our machines are highly maintainable
• Target MTTR is 18 mins. per month