INTENT

TO UPGRADE THE CAPABILITIES OF ALL COMPANY MEMBERS THROUGH EDUCATION,TRAI N-ING AND PARTICIPATION

TPM

OBJECTIVE

TO RESTRUCTURE THE CORPORATE CULTURE THROUGH BEHAVIORIAL CHANGES AND EQUIPMENT IMPROVEMENTS

DEFINITION

A SET OF ACTIVITIES FOR RESTORING EQUIPMENT TO ITS OPTIMAL CONDITION AND CHANGING THE WORK ENVIRONMENT TO MAINTAIN THOSE CONDITIONS THROUGH DAILY MAINTENANCE ACTIVITIES

PURPOSE

TO IDENTIFY PRODUCTIVITY LOSSES AND INVOLVE ALL MEMBERS OF THE COMPANY IN LOSS ELIMINATION PROGRAMS

CONTENTS
WHAT IS TPM BENEFITS OF TPM

PILLARS OF TPM
OPERATOR AUTONOMOUS MAINTENANCE

MEANING OF TPM
TOTAL EFFICENCY MAXIMISATION

T- TOTAL

TOTAL LIFE CYCLE OF PRODUCTION SYSTEM TOTAL MANPOWER COVERAGE PRODUCTIVITY MAXIMISATION BY:

P-PRODUCTIVE

ZERO ACCIDENT
ZERO DEFECT ZERO BREAK DOWN

M-MAINTENANCE

MAINTENANCE COVERS LIFE CYCLE OF PRODUCTION SYSTEM: INDIVIDUAL PROCESSES PLANTS

A BRIEF HISTORY
Total Productive Maintenance 1971-Present

Breakdown Maintenance <1950

Preventive Corrective Maintenance Maintenance 1950-1970 1957-1978

Maintenance Prevention 1960-1980

WHAT ARE THE BENEFITS?

Increased productivity Improved quality Improved skills Safe work environment Job security

PILLARS OF TPM
8 Pillars of TPM (1989 Present)

Focused Improvement
In this Operators And Technical Services Group aim to Focus on specific losses and increase productivity Ensure adequate methods for identification of losses and countermeasure implementation Increase ease of detecting /correcting deterioration of equipment.

Breakdown

Defects
Minor Stoppages C/Over & Adj Tool Change
Reduced Speed Start-up Loss

Seven Big Losses

0%

100 %

FOCUS AREAS IN FOCUSSED IMPROVEMENT

MINIMIZE BREAKDOWN LOSSES ELIMINATE MINOR STOPPAGE LOSS ELIMINATE CHANGE OVER LOSS MINIMIZE SET-UP LOSS

What Is Autonomous Maintenance?

Activities in which each operator performs cleaning,timely inspection,lubrication and consumable parts replacement on their own equipment.

Autonomous Maintenance 7 Steps

Autonomous Maintenance

T P M

Standardization Autonomous Inspection General Inspection

6
5 4 3 2

Prepare Temporary Standards Countermeasures for Hard-To-Access & Source Of Contamination

Initial Clean-up

What Is The Goal Of Operator Autonomous Maintenance?

Keeping one's own equipment in good condition by oneself.

Activities Performed By The Operators

Prevent Deterioration

Measure Deterioration
Restore Deterioration

TPM Roles Of

Establish Basic Conditions

Keep Operation Conditions

Prevent Machine From Deteriorating

Improve Weak Points In Design

Improve Skill

Operators

Maintenance

Management

What Is Planned Maintenance?

Activities in which operators and maintenance men eliminate losses by daily maintenance,control for replacement of parts,why - why analysis of failures, lubrication control and prevention of repeated breakdowns .

PILLAR PLANNED MAINTENANCE

AIM: REALISE EFFICIENCY IN MAINTENANCE DEPARTMENT TO ELIMINATE 8 MAJOR LOSSES METHOD: DAILY MAINT., TBM, CBM, IMPROVEMENT FOR INCREASING THE SERVICE LIFE EXPECTANCY, CONTROL FOR REPLACEMENT, CONTROL FOR REPLACEMENT OF PARTS,FAILURE ANALYSIS AND PREVENTION OF REOCCURRENCE,LUBRICATION CONTROL

7 STEPS OF PLANNED MAINTENANCE

Use eqp to limits Overall equipment diagnosis
Improvement:inspection And mtn efficiency Extension of service life Prepare standards:basic and usage conditions Improvement-difference basic and usage condition:present state?present mtn method Analysis-Basic and usage condition:present state selection of priority parts

7 6 5 4 3 2

T P M

PLANNED MAINTENANCE
WHO?

OPERATOR AND MAINTENANCE MEN

ACTIVITIES FOR PLANNED MAINTENANCE

REDUCTION IN VARIATION OF BREAKDOWN FREQUENCY EXTENSION OF LIFE SPAN ESTABLISHED TIME BASED MAINTENANCE PREDICTION OF FAILURES

REDUCTION IN VARIATION OF BREAKDOWN FREQUENCY

HANDLING LATENT DEFECTS ESTABLISH BASIC CONDITIONS

EXTENSION OF LIFE SPAN

IMPROVE DESIGN WEAK POINTS ELIMINATE INCIDENTAL FAILURES RESTORE EXTERNAL DETERIORATION

ESTABLISHED TIME BASED MAINTENANCE

TIME BASED RESTORATION OF DETERIORATION DETECTION OF SIGN OF ABNORMALITY INSIDE EQUIPMENT THROUGH SENSES

PREDICTION OF FAILURES

PREDICTION OF SERVICES LIFE THROUGH EQUIPMENT DIAGNOSIS TECHNIQUE TECHNOLOGICAL ANALYSIS OF CATASTROPHIC FAILURE

TPM MEASUREMENTS

CHANGE OVER TIME EQUIPMENT CHECK TIME CLEAN-UP TIME MINOR STOPPAGES MAINTENANCE COSTS ACCIDENTS

DOWNTIME 1.PLANNED 2.UNPLANNED # OF EQUIPMENTS FAILURES DEFECT RATE

Equipment Failure Statistic

Of Equipment Failures Are Due 12% To Dirt And Poor Clean-Up Habits
Lubrication Method 13%

Dirt 12%

Lack Of Lubricant 24%

Other Equip. Failures 51%

Source: JIPM

PILLAR EDUCATION AND TRAINING

LEVEL OF OPERATORS AND MAINTENANCE MEN METHOD:BASIC MAINTENANCE STEPSNUTS &BOLTS- KEY MATINGBEARINGS-GEAR TRANSMISSIONLEAKAGE PREVENTION-HYD &PNEUMATIC EQPT-ELECTRICAL CONTROL SYSTEMS

AIM:RAISE THE TECHNICAL SKILL

EDUCATION &TRAINING

WHO? OPERATORS &MAINTENANCE MEN

ANY QUERIES ?

THANKS