Total

Productive
Maintenance(T
PM) By Yigedeb Abay
December 2015
 Contents
1. How does Failure Occur?
2. Evolution of TPM
3. Meaning and Features of TPM
4. Benefits/Comparison of TPM with
other
5. The Six big losses
6. Over all Equipment
Efficiency(OEE)
7. Eight Pillars of TPM
8. Stages in TPM Implementation
 1. How does Failure Occur
1.1. Two types of Failures
1. Unpredictable or sporadic
equipment failures:-These failures
are due to real and visible causes.
This failure occurs randomly with out
any pattern.
2. Deterioration from the basic
condition:-But there are a very
large number of failures, if not most
of them, are due to deterioration from
the basic condition.
 1. How does Failure Occur...
1.2. Fault Development
 Deterioration from the basic condition is
the first step on the way to developing
faults
 There will be a first time the fault
happens, which might not be the
same as the first time it was
recognized as a failure or a problem
 It is only when the complete problem is
analyzed over its lifetime that the true
causes can be identified.
 1. How does Failure Occur...
1.3. What is Basic Condition?
 The basic condition is the condition of
the equipment that is expected to be
in when it was first manufactured and
operating to its original
specification.
 There is also a visual component of
the basic condition: the equipment
should be clean inside and outside.
 Therefore, any machine that misses
technical standards must be checked
2. Evolution of TPM
 2. Evolution of TPM…
2.1. Break Down maintenance
 It means that people wait until
equipment fails and repair it.
 It is mostly adopted when the
equipment failure does not
significantly affect the operation
or production or generate any
significant loss other than repair
cost.
 But mostly it creates unplanned
stoppages, excessive damage, spare
 2. Evolution of TPM…
2.2. Preventive maintenance
 It is a daily maintenance ( cleaning,
inspection, oiling and re-tightening ),
design to retain the Basic/healthy
condition of equipment and
prevent failure through the
 prevention of deterioration,
 periodic inspection or
 equipment condition diagnosis, to
measure deterioration.
 2. Evolution of TPM…
2.2. Preventive maintenance…
 It is further divided into periodic
maintenance and predictive
maintenance.
2.2.1. 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.
 2. Evolution of TPM…
2.2. Preventive Maintenance…
2.2.2. Predictive maintenance
– Service life of important parts are
predicted based on inspection or
diagnosis, in order to use the parts to the
limit of their service life.
– Predictive maintenance is condition based
maintenance.
– Sound (bearing), Temperature (cooling
water/air/oil), Flash on contact points
(sparks), Pressure(components), Electrical
loads (amps, voltage), Fluids/Lubrication
analysis (level, viscosity),
 2. Evolution of TPM…
2.3. Corrective maintenance
 Equipment with design weakness must be
redesigned to improve reliability or
improving maintainability.
 The primary difference between corrective
and preventive maintenance is that a
problem must exist before corrective
actions are taken.
 Maintenance information, obtained from
CM, is useful for maintenance prevention
for the next equipment and improvement
of existing manufacturing facilities.
 2. Evolution of TPM…
2.4. Maintenance Prevention
 It indicates the design of new
equipment.
 Weakness of current machines are
sufficiently studied and solutions are
incorporated before commissioning a
new equipment.
 On site information leading to failure
prevention, easier maintenance and
prevention of defects, safety and
 2. Evolution of TPM…

n ce c e New Equipment Design

n a nan
inte nte
a ) i
a )
M M M
di c TB ive CBM Component redesign
rio ( t
Pe edic (
Pr
Basic Condition Maintenance
Prevention
Preventive Maintenance Corrective
Breakdown Maintenance
Deterioration Maintenance

Equipment Failure
 3. Meaning and Features of TPM
3.1. History of TPM
 Nippon Denso was the first company to
introduce plant wide preventive
maintenance in 1960. It also added
Autonomous maintenance done by
production operators. Using the
established quality circles by then, all
employees took part in implementing
Productive maintenance.

 Preventive maintenance along
with Maintenance
3.1. Definition of TPM
 It is company-wide equipment
management activity that aims to
deploy activities for thoroughly
eliminating equipment-related MUDA
and losses and maximizing
production efficiency throughout the
entire company.

 TPM aims to achieve zero

accidents, zero nonconformities,
3.1. Definition of TPM…
 Total effectiveness indicates TPM’s
pursuit of economic efficiency or
profitability.

 Total participation of all employees

includes autonomous maintenance
by operators through small group
activities.
 3.2. Features of TPM
1. TPM aims to maximize equipment
effectiveness (over all effectiveness).
2. TPM establishes a thorough system of PM
for the equipment’s entire life span.
3. TPM is implemented by various
departments (engineering, operations,
maintenance).
4. TPM involves every single employee, from
top management to workers on the floor.
5. TPM is based on the promotion of PM
through motivation management :
autonomous small group activities.
 3.2. Features of TPM…
1. Operator who understands the
basics of equipment and notices
when something is wrong in quality
and equipment.
2. It builds a system whereby people
“protect one’s own equipment
by oneself.”
3. To be effective TPM must be
implemented on a companywide
 4. Eight Pillars of TPM
1. Autonomous Maintenance
2. Focused Improvement
3. Planned Maintenance
4. Quality Maintenance
5. Education & Training
6. Office TPM
7. Safety, Hygiene and Environment Control
8. Development management
 TPM Foundation-5S
 TPM starts with 5S. Problems cannot
be clearly seen when the work place
is unorganized.
 Making problems visible is the
first step of improvement.
 Pillar-1 Autonomous
Maintenance
 This pillar is geared towards
developing operators to be able to
take care of small maintenance
tasks, thus freeing up the skilled
maintenance people to spend time
on more value added activity and
technical repairs.
 By use of this pillar, the aim is to
maintain the machine in new
condition.
 Pillar-1 Autonomous
Maintenance
 This includes cleaning, lubricating,
visual inspection, tightening of
loosened bolts etc. by operators
Stapes
1. Preparation of employees.
2. Initial cleanup of machines.
3. Take counter measures
4. Fix tentative autonomous maintenance schedule
5. General inspection
6. Autonomous inspection
7. Standardization
 Pillar-2 Continuous
Improvement
 The principle behind is that "a very
large number of small improvements
are more effective in an
organizational environment than a
few improvements of large value.
 Achieve and sustain zero loses with
respect to minor stops, measurement
and adjustments, defects and
unavoidable downtimes.
 Pillar-3 Planned
Maintenance
 With Planned Maintenance we evolve
our efforts from a reactive to a
proactive method and use trained
maintenance staff to help train the
operators to better maintain their
equipment.
Pillar-4 Quality Maintenance
• It is aimed towards customer delight
through highest quality through
defect free manufacturing. Focus is
on eliminating non-conformances in
a systematic manner, much like
Focused Improvement.
• We gain understanding of what
parts of the equipment affect
product quality and begin to
eliminate current quality concerns,
Pillar-4 Quality Maintenance
 Quality defects are classified as
customer end defects and in house
defects. For customer-end data, we
have to get data on
1. Customer end line rejection
2. Field complaints.

In-house, data include data related

to products and data related to
process
 Pillar-5 Education and
Training
 It is aimed to have multi-skilled revitalized
employees whose morale is high and who
has eager to come to work and perform all
required functions effectively and
independently.
 Education is given to 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.
 Pillar-6 Office TPM
• Office TPM should be started after
activating four other pillars of TPM (JH,
Kaizen, QM, PM). Office TPM must be
followed to improve productivity, efficiency
in the administrative functions and identify
and eliminate losses.
• This includes analyzing processes and
procedures towards increased office
automation.
 Pillar-7 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.
 It targets to achieve Zero accident,
Zero health damage and Zero fires.
4.2. Nine Essentials of TPM
1) Self maintained work place
2) Elimination of the 6 big losses
3) Zero Breakdowns
4) Zero Defects
5) Optimal life and availability of tools
6) Self-improvement
7) Short production-development time and
low machine life cost
8) Productivity in indirect departments
9) Zero Accidents
 4.3. The 6 Big losses
1) Breakdown
2) Set-up and Adjustment 　
3) Speed loss
4) Idle Time
5) Minor stoppages
6) Defects and re-work
 5. Over all Equipment
Efficiency(OEE)
 The basic measure associated with Total
Productive Maintenance (TPM) is the OEE.
 This OEE highlights the actual "Hidden
capacity" in an organization.
 OEE is not an exclusive measure of how
well the maintenance department works.
 The design and installation of equipment
as well as how it is operated and
maintained affect the OEE.
 5. Over all Equipment
Efficiency(OEE)

 It measures both efficiency (doing

things right) and effectiveness (doing
the right things) with the equipment.

 It incorporates three basic indicators

of equipment performance and
reliability. Thus OEE is a function of
the three factors mentioned below.
 5. Over all Equipment
Efficiency(OEE)

1. Availability or uptime (downtime:

planned and unplanned, tool change,
tool service, job change etc.)
2. Performance efficiency (actual vs.
design capacity)
3. Rate of quality output (Defects and
rework)
5.1. Overall Equipment
Effectiveness Model
 5.2. Over all Equipment
Efficiency(OEE) calculation
 PE - Performance Efficiency

Net production time is the time during which the

products are actually produced. Speed losses,
small stops, idling, and empty positions in the
line indicate that the line is running, but it is not
providing the quantity it should.
• Q - Refers to quality rate. Which is
percentage of good parts out of total
produced. Sometimes called
“yield”. Quality losses refer to the
situation when the line is producing,
but there are quality losses due to in-
progress production and warm up
rejects. We can express a formula for
quality like this
 Example
1. Running 70 percent of the time (in a 24-
hour day)
2. Operating at 72 percent of design
capacity (flow, cycles, units per hour)
3. Producing quality output 99 percent of
the time

 When the three factors are considered

together (70% availability x 72% efficiency
x 99% quality), the result is an overall
equipment effectiveness rating of 49.9
percent.
 Stages in TPM Implementation
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 an
awareness program, after which announcement is
made to all.
STEP 2 -Initial education and
propaganda for TPM
• Training is to be done based on the need. Some
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 and involve people from
Maintenance; Production; Quality and
Engineering.
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
is the proof of reaching a satisfactory
level.
STEP B - INTRODUCTION STAGE
 This is a ceremony and we should invite
all. Suppliers as they should know that we
want quality supply from them.
 Related companies and affiliated
companies who can be our customers,
sisters concerns etc. Some may learn from
us and some can help us and customers
will get the communication from us that
we care for quality output.
STAGE C - IMPLEMENTATION
 In this stage eight activities are carried
which are called eight pillars in the
development of TPM activity. Of these four
activities are for establishing the system
for production efficiency, one for initial
control system of new products and
equipment, one for improving the
efficiency of administration and are for
control of safety, sanitation as working
environment.
STAGE D - INSTITUTIONALISING
STAGE
 By all there activities one would has reached
maturity stage. Now is the time for applying for
PM award. Also think of challenging level to which
you can take this movement.