National University of

Science and Technology

Topic: Total Productive Maintanance

Department of Industrial and

Manufacturing Engineering
Faculty of Engineering
 Group members
• Nevanji Paradza N02018512H
• Takudzwa matsa
• Tanatswa mugabe N02016836C
• Sailas
• Adonijah Danha N02019616X
• Thabiso Nkomo N02022775Y
• Kudzaishe Makotore N02012313H

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Department of Industrial and Manufacturing Engineering
Faculty of Engineering National University of Science And Technology
 Presentation Outline
• Introduction of Total Production Management
• Explaining Total Production Management
• Describing benefits of Total Production Management

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Department of Industrial and Manufacturing Engineering
Faculty of Engineering National University of Science And Technology
 Introduction
• Total productive maintenance (TPM) is the process of using
machines, equipment, employees and supporting processes to
maintain and improve the integrity of production and the quality of
systems. In other words, it's the process of getting employees
involved in maintaining their own equipment while emphasizing
proactive and preventive maintenance techniques. Total productive
maintenance strives for perfect production. That is:
a) No breakdowns
b) No stops or running slowly
c) No defects
d) No accidents
• It is about harnessing all human and material resources in a company
in the most effective way to achieve an organization's objectives.

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Department of Industrial and Manufacturing Engineering
Faculty of Engineering National University of Science And Technology
 Total productive maintenance
• Instances of Total Productive Maintenance is when there is a
performance of daily, monthly and yearly check-ups, proper
lubrication, air filter changes and sorting, straightening and
shining
• Its focused on archiving zero defects, zero breakdowns and
zero accidents

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Department of Industrial and Manufacturing Engineering
Faculty of Engineering National University of Science And Technology
 Objectives of Total productive maintenance
• Commit all employees at all levels of the organization.
• Commit all departments in the organization to TPM.
• Improve equipment and plant efficiency to a maximum.
• It strives to achieve maximum equipment efficiency at the
lowest life cycle cost (LCC), among other ways through
everybody’s participation.
• Develop systems for productive maintenance to equipment life
cycle costs.

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Department of Industrial and Manufacturing Engineering
Faculty of Engineering National University of Science And Technology
 Total productive maintenance Concept
• Focused Improvement
• Planned Maintenance
• Equipment and Process Improvement
• Early Management of New Equipment
• Process Quality Management
• TPM in the Office

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Department of Industrial and Manufacturing Engineering
Faculty of Engineering National University of Science And Technology
8 Pillars of TPM(Japanese Institute of Plant Maintenance

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Department of Industrial and Manufacturing Engineering
Faculty of Engineering National University of Science And Technology
 8 PILLARS OF TPM
• Total > All employees involved at all levels
• Productive > Effective use of all resource
• Maintenance >Keeping man machine ,material systems in
optimum conditions

Its Focusses : No defects

No Breakdowns
No Accidents
No small stops or slow running

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Department of Industrial and Manufacturing Engineering
Faculty of Engineering National University of Science And Technology
 Focused Improvement

Through small but continues modification to processes, the

overall effectiveness and efficiency of the organization.
• Cross-functional teams are assembled to work on problematic
equipment and come up with improvement suggestions.
• It looks at the process and fids out ideas for how to improve
them.
• Cross functional teams identify recurring problems and ways
to mitigate.

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Department of Industrial and Manufacturing Engineering
Faculty of Engineering National University of Science And Technology
 Autonomous Maintenance

• Empowering operators to work on minor maintenance tasks

effectively allows the maintenance team to focus more on
specialized assignments.
5s Methodology
Seiri > Organize
Seiton > Orderliness
Seiso > Cleanliness
Seiketsu > Standardize
Shitsuke > Sustain

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Department of Industrial and Manufacturing Engineering
Faculty of Engineering National University of Science And Technology
 Quality Maintenance

• One of TPM’s biggest goals is manufacturing zero defective

products, which plays a big role in customer satisfaction.
• The quality aspect of maintenance is very important because it
helps in preventing defects from moving down the value chain
which only leads to a lot of rework.

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Department of Industrial and Manufacturing Engineering
Faculty of Engineering National University of Science And Technology
 Planned Maintenance

• An organization can keep equipment in peak condition by

setting up Planned Maintenance(PM).
• Programmed maintenance that requires machines to shut down
should be done after regular work hours.
• By scheduling these activities around such metrics, the cycle
of breakdowns and failure is broken thus contributing to a
longer service life of machines.

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Department of Industrial and Manufacturing Engineering
Faculty of Engineering National University of Science And Technology
 Early Equipment Maintenance

• Uses the experience gathered from previous maintenance

improvement activities to ensure that new machinery reaches
its optimal performance much early than usual.
• Early equipment maintenance is one of the 8 pillars of a well-
succeeded TPM strategy.

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Department of Industrial and Manufacturing Engineering
Faculty of Engineering National University of Science And Technology
 Training and Education

• TPM requires investing in training and education.

• Without proper training, tools such as TPM can be
misunderstood by the staff which can result in disastrous
results for the company.
• When you think about how fast technology is evolving,
continuous training is the only way to make sure a company’s
technicians are familiar with new equipment and the state-of-
the-art of the industry.

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Department of Industrial and Manufacturing Engineering
Faculty of Engineering National University of Science And Technology
 Safety, Health and Environment

• The health, safety and environment pillar of total productive

maintenance ensures that all workers are provided with an
environment that is safe and that all conditions that are
harmful to their well-being are eliminated.
• TPM also aims at zero work accidents, zero pollution, and zero
burnout.
• Good maintenance management not only avoids accidents
during maintenance activities but also contributes to every
worker’s well-being and safety. 

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Department of Industrial and Manufacturing Engineering
Faculty of Engineering National University of Science And Technology
 Office Total Productive Maintenance

• The last of the 8 pillars is office TPM.

• This means administrative workers and managers should also
contribute, instead of leaving everything to the workers.

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Department of Industrial and Manufacturing Engineering
Faculty of Engineering National University of Science And Technology
 TPM Implementation Involves

• Training and communication to improve the skills of operators

and maintenance staff.
• Continuous Improvement of equipment efficiency by follow up
on operational problems and analyzing the causes of the
problems.
• Self initiated maintenance performed by the operators.
• Activities promoting better quality, safety and environmental
principles(Maintenance for Quality).
• Pilot projects
• Management feedback

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Department of Industrial and Manufacturing Engineering
Faculty of Engineering National University of Science And Technology
 Steps followed in Introducing TPM.
1. Preparatory stage:
a. Inform everyone i.e. the management is to announce to
everyone about TPM production in the organization.
b. Training the personnel according to the need for training.
c. Setting up departmental committees.
d. Establishing the working system and target.
e. A master plan for institutionalizing.

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Department of Industrial and Manufacturing Engineering
Faculty of Engineering National University of Science And Technology
 Steps followed in Introducing TPM.
2. Introduction stage
• A ceremony to which suppliers, connected firms, affiliated
companies that could be our clients, and anybody else engaged is
invited. It is intended to notify them of the quality supply we require
from them as well as the quality we should generate in our products.
3. Implementation
• This is where the activities of the 8 pillars are done.
4. Institutionalizing stage.
• The institutionalizing master plan, i.e. making TPM an
organizational culture, is to be conducted at this stage.

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Department of Industrial and Manufacturing Engineering
Faculty of Engineering National University of Science And Technology
 Organisation structure for TPM Implementation

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Department of Industrial and Manufacturing Engineering
Faculty of Engineering National University of Science And Technology
 Benefits of TPM

• Accidents are reduced considerably.

• Manufacturing cost is reduced considerably by up to 30%.
• Improved working environment.
• Better and more energy saving measures.
• Reduction in delays and downtime losses by reducing
breakdowns and equipment failures.
• Attracting future investments

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Department of Industrial and Manufacturing Engineering
Faculty of Engineering National University of Science And Technology
 Challenges of TPM implementation

• Inadequate Knowledge of TPM

• Lack of Leadership and Management
• Resistance to change
• Lack of reward programme
• Inadequate Workshops and Trainings
• Excess Inventory

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Department of Industrial and Manufacturing Engineering
Faculty of Engineering National University of Science And Technology
 TPM Improvement Plan

• The measurement cycle which involves collecting equipment

history and performance information.

• The condition cycle which includes developing future asset

care and carrying out a critical assessment of the equipment.

• The problem prevention cycle which includes problem

prevention and developing best practices.

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Department of Industrial and Manufacturing Engineering
Faculty of Engineering National University of Science And Technology