TP

M
 What is TPM
Definition of TPM
TPM is a corporate culture to maximize
production system effectiveness and reducing chronic losses
to zero by involvement of all employees and practicing
Genba-Genbutsu (Actual seen on shop floor).

T - Total (Total employee, Total activity, Total equipments)

P - Productive (Output with zero delay)
M - Maintenance & Management
 Why is TPM required
1. To reduce cost of manufacturing by eliminating
waste. (Equipment breakdown, set-up time,
defective product etc.)
2. To achieve defect free production by enhancing
knowledge / control over process & equipment
3. Small lot production of various kinds of product
4. To Shortening of lead time.
5. To make work place safe & clean
 Goal of TPM
1. Zero accident
2. Zero defect
3. Zero Breakdown
4. Zero delays
Achieving maximum efficiency of Total
employee, Total activity, Total equipments.
 Unique features of TPM
Maintenance by operator
This the unique feature of TPM over Productive
maintenance (Profitability) & preventive
maintenance (System for MP, PM & CM)

A brief History
TPM is a unique Japanese system developed
from the PM concept (Preventive or productive
maintenance) of U.S.A
 Progress of TPM
TPM (1971) (Nippon Denso Co.)

Maintenance prevention (1960)

Corrective maintenance (1957)

Preventive Maintenance (1951)

 Basic Concept of TPM
1. Building up a profitable corporate culture
 Pursuing economic efficiency and zero accident, zero
defect, zero failure.
2. Prevention philosophy
 Maintenance prevention, Preventive maintenance,
Corrective maintenance
3. Participation of all
 Organising overlapping small groups in an hierarchical
system, “Jishu Hozen” activities by operators
4. Genba-genbutsu approach
 Maintain equipment and process in must be condition by
visual indication & control
5. Automatization and unmanned plant operation
 Creating the unmanned working environment
 Improvement in corporate
culture with TPM
Improving Human resources by educating operator to
perform “Jishu Hozen”, Maintenance man to prevent
breakdown & Production engineer for efficient utilization of
equipment

Improving plant equipment by attaining maximum

efficiency from existing equipment & design of new
equipment considering the Life Cycle Cost and vertical start
up

Restructure the corporate culture through improvement of

human resources and plant equipment
Autonomous
Maintenance

Kobetsu-Kaizen

Planned
Maintenance

Quality
Maintenance
TPM

Development
Management

Education &
8 Pillars of TPM

Training

Safety, Health
& Environment

TPM in Offices