Total Preventive Maintenance (TPM) is a production management approach that places the responsibility for routine maintenance on the

workers who operate the machinery, rather then employing separate maintenance personnel for that function. Used in many Japanese companies, TPM gives employees "a sense of responsibility and awareness of the equipment they use and [cuts] down on abuse and misuse of the equipment," William J. Stevenson wrote in his book Production/Operations Management. TPM is increasingly being used in manufacturing environments in the United States. It holds particular appeal for small manufacturers. The term maintenance is used to describe the various efforts businesses make toward keeping their facilities and equipment in good working order. It encompasses both breakdown maintenancea policy that involves dealing with problems as they occur and attempting to reduce their impact on operationsand preventive maintenancea policy that involves using such measures as inspecting, cleaning, adjusting, and replacing worn parts to prevent breakdowns from occurring in the first place. Preventive maintenance is performed periodically in order to reduce the incidence of equipment failure and the costs associated with it. These costs include disrupted production schedules, idled workers, loss of output, and damage to products or other equipment. Preventive maintenance can be scheduled to avoid interfering with production. Common methods of planning preventive maintenance are based on the passage of time, on the amount of usage the equipment receives, and on an as-needed basis when problems are uncovered through inspections. Ideally, preventive maintenance will take place just before failure occurs in order to maximize the time that equipment is in use between scheduled maintenance activities. As Stevenson explained, the goal for production managers is to find a balance between preventive maintenance and breakdown maintenance that will minimize the company's overall maintenance costs. "Decision makers try to make a trade-off between these two basic options that will minimize their combined cost," he noted. "With no preventive maintenance, breakdown and repair costs would be tremendous. Furthermore, hidden costs, such as lost production and the cost of wages while equipment is not in service, must be factored in. So must the cost of injuries or damage to other equipment and facilities or to other units in production. However, beyond a certain point, the cost of preventive maintenance exceeds the benefit."

The decision of how much maintenance to perform involves the age and condition of the equipment, the complexity of technology used, the type of production process, and other factors. For example, managers would tend to perform more preventive maintenance on older machines because new ones have only a slight risk of breakdown and need less work to stay in good condition. It is also important to perform routine maintenance prior to beginning a particularly large or important production run. In TPM, production employees are trained in both operating procedures and routine maintenance of equipment. They perform regular inspections of the machinery they operate and replace parts that have become worn through use before they fail. Since the production employees spend so much time working with the equipment, they are likely to pick up small signals that a machine is in need of maintenance. Among the main benefits of TPM is that employees gain a more complete understanding of the functioning of the system. TPM also gives them increased input into their own productivity and the quality of their work. Various types of maintenance strategies 1. Reactive Maintenance Reactive maintenance is basically the "run it till it breaks" maintenance mode. No actions or efforts are taken to maintain the equipment as the designer originally intended to ensure design life is reached. Advantages to reactive maintenance can be viewed as a double-edged sword. If we are dealing with new equipment, we can expect minimal incidents of failure. If our maintenance program is purely reactive, we will not expend manpower dollars or incur capitol cost until something breaks. Advantages Low cost. Less staff. Disadvantages Increased cost due to unplanned downtime of equipment. Increased labor cost, especially if overtime is needed. Cost involved with repair or replacement of equipment. Possible secondary equipment or process damage from equipment failure. Inefficient use of staff resources 2. Preventive Maintenance Preventive maintenance can be defined as follows: Actions performed on a time- or machinerun-based schedule that detect, preclude, or mitigate degradation of a component or system

with the aim of sustaining or extending its useful life through controlling degradation to an acceptable level. Advantages Cost effective in many capital intensive processes. Flexibility allows for the adjustment of maintenance periodicity. Increased component life cycle. Energy savings. Reduced equipment or process failure. Estimated 12% to 18% cost savings over reactive maintenance program. Disadvantages Catastrophic failures still likely to occur. Labor intensive. Includes performance of unneeded maintenance. Potential for incidental damage to components in conducting unneeded maintenance. 3. Predictive Maintenance Predictive maintenance can be defined as follows: Measurements that detect the onset of a degradation mechanism, thereby allowing causal stressors to be eliminated or controlled prior to any significant deterioration in the component physical state. Results indicate current and future functional capability. Basically, predictive maintenance differs from preventive maintenance by basing maintenance need on the actual condition of the machine rather than on some preset schedule. You will recall that preventive maintenance is timebased. Activities such as changing lubricant are based on time, like calendar time or equipment run time. For example, most people change the oil in their vehicles every 3,000 to 5,000 miles traveled. This is effectively basing the oil change needs on equipment run time. No concern is given to the actual condition and performance capability of the oil. It is changed because it is time. This methodology would be analogous to a preventive maintenance task. If, on the other hand, the operator of the car discounted the vehicle run time and had the oil analyzed at some periodicity to determine its actual condition and lubrication properties, he/she may be able to extend the oil change until the vehicle had traveled 10,000 miles. This is the fundamental difference between predictive maintenance and preventive maintenance, whereby predictive maintenance is used to define needed maintenance task based on quantified material/equipment condition. The advantages of predictive maintenance are many. A well-orchestrated predictive maintenance program will all but eliminate catastrophic equipment failures. We will be able to schedule maintenance activities to minimize or delete overtime cost. We will be able to minimize inventory and order parts, as required, well ahead of time to support the downstream maintenance needs. We can optimize the operation of the equipment, saving energy cost and increasing plant reliability. Past Advantages Increased component operational life/availability. Allows for preemptive corrective actions. Decrease in equipment or process downtime. Decrease in costs for parts and labor. Better product quality. Improved worker and environmental safety. Improved worker moral. Energy savings. Estimated 8% to 12% cost savings over preventive maintenance program.

Disadvantages Increased investment in diagnostic equipment. Increased investment in staff training. Savings potential not readily seen by management. 4. Reliability Centered Maintenance RCM: "a process used to determine the maintenance requirements of any physical asset in its operating context." Basically, RCM methodology deals with some key issues not dealt with by other maintenance programs. It recognizes that all equipment in a facility is not of equal importance to either the process or facility safety. It recognizes that equipment design and operation differs and that different equipment will have a higher probability to undergo failures from different degradation mechanisms than others. It also approaches the structuring of a maintenance program recognizing that a facility does not have unlimited financial and personnel resources and that the use of both need to be prioritized and optimized. In a nutshell, RCM is a systematic approach to evaluate a facility's equipment and resources to best mate the two and result in a high degree of facility reliability and cost-effectiveness. RCM is highly reliant on predictive maintenance but also recognizes that maintenance activities on equipment that is inexpensive and unimportant to facility reliability may best be left to a reactive maintenance approach. The following maintenance program breakdowns of Advantages Can be the most efficient maintenance program. Lower costs by eliminating unnecessary maintenance or overhauls. Minimize frequency of overhauls. Reduced probability of sudden equipment failures. Able to focus maintenance activities on critical components. Increased component reliability. Incorporates root cause analysis. Disadvantages Can have significant startup cost, training, equipment, etc. Savings potential not readily seen by management. PRINCIPLES OF FACILITY (PLANT) LAYOUT Facility layout problem is a multi criteria problem. Numerous factors, such as location of work centers, offices, computer centre, design and drawing section, tool-room, storage space, utilities, etc., are to be considered. The principles of good facility layout involve :. 1. Least material handing cost 2. Worker effectiveness 3. High productivity and effectiveness 4. Group technology What are the objectives, principles and types of Plant Layout? Plant layout is a mechanism which involves knowledge of the space requirements for the facilities and also involves their proper arrangement so that continuous and steady movement of the production cycle takes place. Moore, a very well known name in the business world, explained plant layout as, The plan of or the act of planning, an optimum arrangement of facilities, including personnel, operating 4

equipment, storage space, materials handling equipment and all other supporting services along with the design of the best structure to accommodate these facilities. The problems related to plant layout are generally observed because of the various developments that occur. These developments generally include adoption of the new standards of safety, changes in the design of the product, decision to set up a new plant, introducing a new product, withdrawing the various obsolete facilities etc. Objectives of a good plant layout are 1. Providing comfort to the workers and catering to workers taste and liking. 2. Giving good and improved working conditions. 3. Minimizing delays in production and making efficient use of the space that is available. 4. Having better control over the production cycle by having greater flexibility for changes in the design of the product. Principles of a good plant layout are 1. A good plant layout is the one which is able to integrate its workmen, materials, machines in the best possible way. 2. A good plant layout is the one which sees very little or minimum possible movement of the materials during the operations. 3. A good layout is the one that is able to make effective and proper use of the space that is available for use. 4. A good layout is the one which involves unidirectional flow of the materials during operations without involving any back tracking. 5. A good plant layout is the one which ensures proper security with maximum flexibility. 6. Maximum visibility, minimum handling and maximum accessibility, all form other important features of a good plant layout. Types of layouts 1. Process layout These layouts are also called the functional layouts and are very suitable in the conditions, when the products being prepared are non standard or involve wide variations in times of processing of the individual operations. Such layouts are able to make better utilization of the equipment that is available, with greater flexibility in allocation of work to the equipment and also to the workers. Imbalance caused in one section is not allowed to affect the working of the other sections. 2. Product layout These layouts are also known as the line layouts or the layout by sequence. In such layouts, the manufacturing cycle is small with minimum material handling. The space required is small and quality control is easy to exercise. 3. Project layout Such layouts are also referred to as the fixed position layouts. In these layouts, the components, heavy materials, sub assemblies all remain fixed at one place and the job is completed by movement of machines, men and tools to the location of the operations. General principles Plant layout is often a compromise between a number of factors such as:

The need to keep distances for transfer of materials between plant/storage units to a minimum to reduce costs and risks; The geographical limitations of the site;

Interaction with existing or planned facilities on site such as existing roadways, drainage and utilities routings; Interaction with other plants on site; The need for plant operability and maintainability; The need to locate hazardous materials facilities as far as possible from site boundaries and people living in the local neighbourhood; The need to prevent confinement where release of flammable substances may occur; The need to provide access for emergency services; The need to provide emergency escape routes for on-site personnel; The need to provide acceptable working conditions for operators. The most important factors of plant layout as far as safety aspects are concerned are those to:

Prevent, limit and/or mitigate escalation of adjacent events (domino); Ensure safety within on-site occupied buildings; Control access of unauthorised personnel; Facilitate access for emergency services. The following are some important factors, which influence the planning of effective layout to a significant degree. 1. Nature of the product: The nature of the product to be manufactured will significantly affect the layout of the plant. Stationary layout will be most suitable for heavy products while line layout will be best for the manufacture for the light products because small and light products can be moved from one machine to another very easily and, therefore, more attention can be paid to machine locations can be paid to machine locations and handling of materials. 2. Volume of production: Volume of production and the standardization of the product also affect the type of layout. If standardized commodities are to be manufactured on large scale, line type of layout may be adopted. 3. Basic managerial policies and decisions: The type of layout depends very much on the decisions and policies of the management to be followed in producing the commodity with regard to the size of plant, kind and quality of the product, scope for expansion to be provided for, the extent to which the plant is to be integrated, amount of stocks to be carried at anytime, the kind of employee facilities to be provided etc. 4. Nature of plant location: The size shape and topography of the site at which the plant is located will naturally affect the type of layout to be followed in view of the maximum utilization of the space available .For e.g., if a site is near the railway line the arrangement of general layout for receiving and shipping and for the best flow of production in and out the plant may be made by the side of the railway lines .If space is narrow and the production process is lengthy, the layout of plant may be arranged on the land surface in the following manner:

5. Type of industry process: This is one of the most important factors influencing the choice of type of plant layout. Generally the types of layout particularly the arrangement of machines and work centers and the location of workmen vary

according to the nature of the industry to which the plant belongs. For the purpose of lay out, industry may be classified into two broad categories: (i) Intermittent and (ii) continuous. Intermittent type of industries is those, which manufacture different component or different machines. Such industries may manufacture the parts, when required according to the market needs. Examples of such industries are shipbuilding plants. In this type of industry functional layout may be the best. The second type of industry in continuous industry. in this type of industry raw material are fed at one end and the finished goods are received at another end. A continuous industry may either be analytical or synthetic . A analytical industry breaks up the raw material into several parts during the course of production process or changes its form, e.g. oil and sugar refineries. A synthetic industry on the other hand mixes the two or more materials to manufacture one product along with the process of production or assembles several parts to get finished product. Cement and automobiles industries are the examples of such industry. Line layout is more suitable in continuous process industries. 6. Types of methods of production: Layout plans may be different according to the method of production proposed to be adopted. Any of the following three methods may be adopted for production- (1) Job order production, (2) batch production, and (3) mass production. Under job production goods are produced according to the orders of the customers and therefore, specification vary from customer to customer and the production cannot be standardized. The machines and equipment can be arranged in a manner to suit the need of all types of customers. Batch production carries the production of goods in batches or group at intervals. In this type of manufacturing the product is standardized and production is made generally in anticipation of sales. In such cases functional or process layout may be adopted. In case of mass production of standardized goods, line layout is most suitable form of plant layout. 7. Nature of machines: Nature of machines and equipment also affects the layout of plants. If machines are heavy in weight or create noisy atmosphere, stationery layout may reasonably be adopted. Heavy machines are generally fixed on the ground floor. Ample space should be provided for complicated machines to avoid accidents. 8. Climate: Sometimes, temperature, illumination and air are the deciding factors in the location of machines and their establishments. For example, in lantern manufacturing industry, the spray-painting room is built along the factory wall to ensure the required temperature control and air expulsion and the process of spray painting may be undertaken. 9.Nature of material: Design and specification of materials, quantity and quality of materials and combination of materials are probably the most important factors to be considered in planning a layout. So, materials storage, space, volume and weight of raw materials, floor load capacity, ceiling height ,method of storing etc. should be given special consideration. This will affect the space and the efficiency of the production process in the plant. It will facilitate economic production of goods and prompt materials flow and soundly conceived materials handling system. 10. Type of machine: Machines and equipment may be either general purpose or special purpose. In addition certain tools are used. The requirements of each machine and equipment are quite different in terms of their space; speed and material handling process and these factors should be given proper consideration while choosing out a particular type of layout. This should also be considered that each machine and equipment is used to its fullest capacity because machines involve a huge investment. For instance, under product layout, certain machines may not be used to their full capacity so care should be taken to make full use of the capacity of the machines and equipment. 12.Human factor and working conditions: Men are the most important factor of production and therefore special consideration for their safety and comforts should be given while planning a layout, specific safety items like obstruction-free

floor, workers not exposed to hazards, exit etc. should be provided for. The layout should also provide for the comforts to the workers such as provision of rest rooms, drinking water and other services etc. sufficient space is also to be provided for free movement of workers. 13. Characteristics of the building: Shape of building, covered and open area, number of storeys, facilities of elevators, parking area and so on also influence the layout plan. In most of the cases where building is hired, layout is to be adjusted within the spaces available in the building. Although minor modification may be done to suit the needs of the plants and equipment. But if any building is to be constructed, proper care should be given to construct it according to the layout plan drawn by experts. Special type of construction is needed to accommodate huge or technical or complex or sophisticated machines and equipment.