TPM Basics

Maintenance - Valves Division KSB PUMPS Ltd.
MPA Maintenance
MPA Maintenance
Total Productive Maintenance (TPM) is a maintenance
program concept.Philosophically,TPM resembles
Total Quality Management (TQM) in several aspects, such as

(1)total commitment to the program by upper level
management is required,

(2) employees must be empowered to initiate
corrective action, and

3) a long range outlook must be accepted as TPM

may take a year or more to implement and is an on-going
process.
Changes in employee mind-set toward their
job responsibilities must take place as well.
MPA Maintenance
TPM evolved from TQM, which evolved as a direct result
of Dr. W. Edwards Deming's influence on Japanese industry.
Dr. Deming began his work in Japan shortly after
World War II. As a statistician.
Dr. Deming initially began to show the Japanese how to
use statistical analysis in manufacturing and how to use the
resulting data to control quality during manufacturing.

The initial statistical procedures and the resulting quality
control concepts fueled by the Japanese work ethic soon
became a way of life for Japanese industry.

This new manufacturing concept eventually became knows
as Total Quality Management or TQM.
History of TPM
MPA Maintenance
Main manufacturing excellence approach of Toyota and
other excellent Japanese companies since the 70s

TPM is the foundation for JIT FA Poke Yoke, Lean
Manufacturing & Zero Defects

Comes from the best of Japanese Industrial Excellence
and evolved from the heat of the continuing Energy Crisis
and Globalization Challenges to achieve more with Less

Background of TPM
MPA Maintenance
TPM brings maintenance into focus as a necessary
and vitally important part of the business.

It is no longer regarded as a non-profit activity.

Down time for maintenance is scheduled as a part
of the manufacturing day and, in some cases, as an
integral part of the manufacturing process.

It is no longer simply squeezed in
whenever there is a break in material flow.

The goal is to hold emergency and
unscheduled maintenance to a minimum.
What For TPM?
MPA Maintenance
T Total Overall efficiency.
Total production system.
Participation of all employees.

P Productive Zero defect.
No trouble in operation.
Safety.

M Maintenance Longer life cycle of production
system.
What is TPM?
MPA Maintenance
Aims at Breakthrough improvement in productivity and
reducing chronic losses to zero.
Aims at Creating a bright, clean, and pleasant factory.
Means To reinforce people and facilities and through them,
the whole organization.
Addresses Overall equipment effectiveness.
Institutionalizes Total Employees Involvement
Participative management and an Overall-small group
organization.
Eliminates inter departmental walls and facilitates Cross
Functional Management.
Is material oriented; it seeks to keep equipment in its intended
condition.

What is TPM?
MPA Maintenance
TPM Results in
Results in building up corporate culture that thoroughly pursues
production
System efficiency improvement OEE (Overall Equipment
efficiency-)
Constructs a system to prevent every kind of loss, for example
Zero accidents, Zero defects and Zero failures based Gemba
(Work Place) and Genbutsu (actual thing) over the entire life
cycle of a production system.
Covers all departments including production, Quality Control,
Purchase, marketing, Administration, Design & development,
Maintenance & Engineering.
Requires all and full involvement from top management to
frontline employees. It builds up an overlapping multidiscipline
process based management teams to achieve excellence
MPA Maintenance
OEE = A x P x Q
A= Availability
P= Performance
Q= Quality
What is OEE?
Overall Equipment Efficiency
MPA Maintenance
Availability =
Standard time
Standard time downtime
Performance =
Components Produced
Components supposed to be Produced
Quality =
Total Acceptable Components
Total Components produced
How to Calculate OEE?
MPA Maintenance
Rising cost of raw material
Higher power cost & specific
power
Higher specific fuel consumption
Higher man power cost
Heavy losses, low profit due to
equipment failures / low reliability /
indifferent attitude
Lower skill levels and involvement
Compartmentalization,
lack of horizontal communication
Low moral/ organizational politics
Unsafe working
Pressure from TOP to progress fast
Easy funds for /capacity build up
Market demand / consumption
sluggish, High quality competition
in the market
Result -Stiff competition, low
returns
Opportunity to earn profit
Increasing quality consciousness
in market
New plants very efficient and cost
effective.
Increasing input material cost
Increasing wages and salaries.
CRISIS FOR THE COMPANY
MARKET CIRCUMSTANCES IN-HOUSE CIRCUMSTANCES
Why TPM?
MPA Maintenance
May decide to adopt TPM

To improve equipments operating efficiency and reliability
Thereby achieve cost reduction. Market share expansion.

Skill development. Zero loss, add profits
High productivity full employee involvement & dynamic
team
Cost reduction through loss control
Market share expansion /customer satisfaction
INCREASED PROFITABILITY
Skill up-gradation
Reduced distribution cost
Reduced equipment failure
Employees involvement
Need for a system which focus on:
MPA Maintenance

Employee Involvement

Top management Commitment

Management Tools

Productivity enhancement

Cost Reduction

Delivery period shortening

Sales Expansion

RESULTS EXPECTED ESSENTIAL REQUIREMENTS
Effectiveness of TPM
MPA Maintenance
The process adopted is a proven methodology based on:
1. Understanding the current status
2. Setting up an organisation
3. Training people
4. Identifying model areas and machines for initial improvement
5. Improvement of Model machines to the original condition and
achievement of zero loss concept. Each machine is to be
improved by a Cross Functional Team consisting of 1 team
leader (Manager Level) and 5-6 members consisting of
Engineer/Supervisor level.
6. Horizontal deployment of the approach to the rest of the plant
7. Finally covers entire organization and involve every employee
from top to bottom.
Process
MPA Maintenance
16 major Losses
1. Equipment failure loss
2. Set up & adjustment loss
3. Cutting tool and jig change loss
4. Start up loss
5. Minor Stoppage and idling loss
6. Reduced speed loss
7. Defects &rework loss
8. Shutdown loss
9. Management loss
10. Operating motion loss
11. Line organization loss
12. Logistics loss
13. Measurement and adjustment loss
14. Energy Loss
15. Die, Tool and Jig loss
16. Yield loss

EQUIPMENT LOSS
MAN LOSS
MATERIAL& ENERGY LOSS
MPA Maintenance
7 Types of Waste
1. Over Production waste

2. Inventory waste

3. Conveyance waste

4. Defect production waste

5. Idle time waste

6. Process related waste

7. Operation related waste
MPA Maintenance
P PRODUCTIVITY To achieve planned production.

Q QUALITY To improve product & process quality.

C COST To reduce cost

D DELIVERY To meet delivery targets

S SAFETY To maintain safety

M MORALE To improve morale

PQCDSM To be calculated & improved by using PDCA cycle.
Set PQCDSM target in all areas
MPA Maintenance
SDCA- PDCA Cycle
Focus
on
Vital
few
A S
D C
DO
Improvement
PLAN
Improvement
Improvement
Activities
ACT
TO Improve the
standards or its use

CHECK the work
against the standard
Routine
work
D C
A P
CHECK
Improvement
results
ACT
standardize
to results or
plan for next
improvement
cycle
Standardization
Initiate improvement
Know the
STANDARD
DO
the work
according to
the standard
MPA Maintenance
POINTS TO IMPROVE
Throw out the Traditional concepts of manufacturing methods

Think of How the new method will work: not how it wont

Dont accept excuses

Correct Mistakes the moment they are found

Problems give you the chance to use your Brain

Ask WHY five times

Ten persons ideas are better than one persons knowledge
MPA Maintenance
A - Type
B - Type
C - Type
Action : This stage
Tool to be used : Y Y analysis
Tool to be used : PM analysis Tool to be used : E & T
Action taken this stage
Problem
Problem Resolved
without any action
chances of reoccurrence
Problem Resolved
chances of reoccurrence
No Action : This stage
Problem
Problem
Problem Resolved
No chances of reoccurrence
MPA Maintenance
7 QC Tools

1) Check sheet

2) Pareto diagram

3) Cause & effect Diagram

4) Graph & control charts

5) Histogram

6) Stratification

7) Scatter diagram
MPA Maintenance
5

S

P
M

Q
M

E
&
T

D
M

S
H
E

J
H

O
T
P
M

MPA Maintenance
MPA Maintenance
2 JISHU HOZEN
THIS PILLAR DEVELOPS OPERATOR TO TAKE CARE OF SMALL MAINTENANCE TASKS .
RESULTING SKILLED MAINTENACE TEAM TO CONCETRATE ON VALUE ADDED AND
TECHNICAL REPAIRS .

THE OPERATOR RESPONSIBLE FOR UP KEEP OPF THEIR EQUIPMENT TO PREVENT IT
FROM DETERIORATING
7STEPS
1. Initial cleaning
2. Counter measures for the causes of forced deterioration& improve hard to access
3. Preparation of tentative JH standards
4. General inspection
5. Autonomous Inspection
6. Standardization
7. Autonomous Management
MPA Maintenance
3 PLANNED MAINTENANCE
THIS PILLAR AIMED TOWARDS

TROUBLE FREE MACHINES AND EQUIPMENTS

PRODUCING DEFECT FREE PRODUCTS FOR TOTAL CUSTOMER SATISFACTION

FOUR CATEGORIES

PREVENTIVE MAINTENANCE
BREAK DOWN MAINTENANCE
CORRECTIVE MAINTENANCE
MAINTENANCE PREVENTION

BENEFITS

ACHIEVE AND SUSTAINAVAILABILITY OF MACHINES
OPTIMUM MAINTENANCE COST
REDUCES SPARES INVENTORY
IMPROVE RELIABILITY AND MAINTENABILITY OF MACHINES
MPA Maintenance
11 Steps Approach to Zero Break down
Phase 1 : Change to natural deterioration by
eliminating
factors of accelerated deterioration.

Phase 2 : Extend inherent service life of
equipment by corrective maintenance
( Improvements to overcome design
limitations)
Phase 3 : Research natural deterioration pattern.
Study how deterioration increases over
time
Phase 4 : Search which parameter to measure
for deterioration

Phase 5 : Implement predictive maintenance

Five Phases for concrete actions against breakdown
1. Classify B/D data ( Including
Equipment Ranking)
2. Analysis of present status QC
Approach
3. Eliminate forced deterioration
4. Find out root cause & implement
countermeasure
5. Identify breakdown recurrence /
understand phenomenon
6. Investigate weakness & improve it

7. Investigate natural deterioration
8. Set deterioration pattern

9. Select & evaluate maintenance point &
standard
10. Decide PM / TBM / CBM
11. Build best maintenance procedure
Approach to Zero breakdown
MPA Maintenance
4 QUALITY MAINTENANCE

CUSTOMER DELIGHT THROUGH HIGHEST QAULITY
DEFECT FREE MANUFACTURING
ELIMINATING NON CONFORMANCES IN A SYSTMATIC MANNER
REACTIVE TO PROACTIVE LIKE (QUALITY CONTROL TO QUALITY ASSURANCE)

BENEFITS

1. DEFECT FREE CONDITION AND CONTROL OF EQUIPMENTS
2. QM ACIVITY TO CONTROL QUALITY ASSURANCE
3. FOCUS OF PREVENTION OF DEFECTS AT SOURCE
4. FOCUS ON POKA-YOKE (FOOL PROOF SYSTEM)
5. IN LINE DETECTION AND SEGREGATION OF DEFECTS
6. EFFECTIVE IMPLEMENTATION OF OPERATOR QUALITY ASSURANCE
7. ACHIEVE & SUSTAIN CUSTOMER COMPLAINT ZERO
MPA Maintenance
5 EDUCATION TRAINING

DEVELOPING MULTISKILL EMPLOYEES WHOSE MORALE IS HIGH AND WHO HAS
EAGER TO COME TO WORK AND PERFORM ALL REQUIRED FUNCTIONS
EFFECTIVELY AND INDEPENDENTLY

EMPLOYEES WILL BE TRAINED TO ADDRESS THE PROBLEM BY FINDING THE
ROOT CAUSE & ELIMINATING THEM

THE GOAL IS TO CREATE A FACTORY FULL OF EXPERTS

BENEFITS

1. ACHIEVE AND SUSTAIN ZERO LOSSES DUE TO LACK OF KNOWLEDGE /SKILLS
/TECHNIQUE

2. REMOVE FATIGUE AND MAKE WORK MORE ENJOYABLE

3. UPGRADING THE OPERATING & MAINTENACE SKILLS
MPA Maintenance
6 DEVELOPMENT MANAGEMENT

Collection & utilization of feedback information regarding present products before
the start of the design.- like MP sheet.

Measuring needs for Easy of manufacturing by analyzing the process for present products.

Measuring needs for Easy of manufacturing by analyzing process of new products in the
stage of planning & design of products.

By identifying failures possibilities based on design reviews of new products.

By identifying failures possibilities based on trail manufacturing & test of new products.
BENEFITS

1. REDUCES LEAD TIME TO NEW PRODUCT LAUNCH
2. REDUCE THE LOSSES
3. COST EFFECTIVE
MPA Maintenance
7 SAFETY HEALTH ENVIROMENT

CREATE SAFE WORK PLACE AND SAFE WORK PRACTICE

THIS PILLAR PLAY VITAL ROLE WITH OTHER PILLARS ON REGULAR BAISI

BENEFITS

ZERO ACCIDENT

ZERO FIRES

ZERO HELATH DAMAGES

SAFE WORKING CONDITION

SAFE WORK PRACTICE

MPA Maintenance
8 OFFICE TPM

TO IMPROVE PRODUCTIVITY

EFFICIENCY IN THE ADMINSTRATIVE FUNCTIONS AND IDENTIFY TO ELEMINATE
LOSSES

ANALYZYING PROCESSES AND PROCEDURES TOWARDS INCREASED OFFICE
AUTOMATION

BENEFITS

INVENTORY REDUCTION

LEAD TIME REDUCTION OF CRITICAL PROCESS

EQUILISING THE WROK LOAD

RETRIEVAL TIME REDUCTION (REDUCE REPETITIVE WORK)

BETTER UTYILIZED WORK AREA

REUDCTION IN ADMINISTRATIVE COSTS

MPA Maintenance
Practice TPM to Attain our Goals
INCREASE IN ASSET UTILIZATION AND EQUIPMENT OEE

FOSTER PRODUCTION EQUIPMENT OWNERSHIP

EQUIPMENT BREAK DOWN PREVENTION (PLANNED MAINTENANCE
THROUGH CM TBM &CBM

DEFECT PREVENTION (QM PROCESS & POKA YOKE)

EVOLVING IN TO SELF DIRECTED WORK TEAMS (SDWTS )& Lean Manufacturing
MPA Maintenance

TPM Basics

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