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Definition

Maintenance is defined as the

management, control, execution
and quality assurance of
activities which ensure the
achievement of optimum
availability and performance of a
plant in order to meet business
objectives.

TPM Meaning

TPM is a partnership between

the maintenance and production
organization to improve product
quality, reduce waste, reduce
cost, increase equipment
availability and improve
maintenance state.

EVOLUTION OF
MAINTENANCE
First
Generation

Second
Generation

Third
Generation

Fix it when
it broke

Higher plant
availability
Longer
equipment life
Lower Costs

1940

1950 1960

Higher plant
reliability and
availability
Greater safety
Better quality
Longer
equipment life
Cost
Effectiveness

1970 1980

1990

2000

TYPES OF MAINTENANCE

Corrective (or) breakdown

maintenance
It implies that repairs are made after
failure of machine or equipment

Scheduled (or) Routine maintenance

It is a stitch-in-time procedure aimed to
avoiding breakdowns

TYPES OF MAINTENANCE

Preventive maintenance
It is carried out before the failure arises
(or) prior to the equipment actually
breakdowns. E.g. Overhauling & Periodic
upkeep.

Predictive maintenance
Equipment Condition evaluated
periodically and maintenance carried
out.

OBJECTIVES OF TPM
Improve Equipment Effectiveness
Achieve Autonomous
Plan Maintenance
To Train all staff in maintenance
skills
To Zero Breakdowns

Cost Trade-off Between PM &

CM
1000
C
o 650
s
t
i
n
R
u
p
e
e

Total cost of
maintenance
Maintenance Activity Costs
(PM)

500
Breakdown Penalty
costs (CM)

50
0

LOW

MEDIUM
MAINTENANCE

HIGH

BIG LOSSES
1. Breakdowns

Long interruptions,
Costly Repairs

2. Setup and
changeover

Taking Longer time

than needed

3. Idling time and

stoppages

Hard to quantify, add

to big losses

4. Reduced speed

Equipment cycle time

reduces

5. Defects and reworks

Quality losses &

Unhappy customer

BENEFIT
S
Increased productivity
Equipment reliability
Reduced down time
Increased plant capacity
Low production maintenance costs
Team work Between Production & Maintenance
People
Improved safety & Profit

THANK YOU