Content :

1. TPM
PICL INDIA PVT LTD

Training Course

Prepared By: Innovation Team

Leadership Through Innovation

TPM Definition
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.
Members:

Supervisors
Manager Operators
/Engineers

T Total All Members

Perfect
P Production
Complete
Production

M Management Management

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Necessity of TPM
 Why TPM now ?

Business environment Benefits from TPM

 Cost reduction to survive

 High quality, Low price •Dramatic cost reduction through maximum
 Increase in the Cost of equipment equipment(production) efficiency

All
Stringent requirement for quality

All this can beachieved

•Set the condition against defective products

this
 Zero defects
•Manage the condition against defective products

through
throughTPM
can be
 Small quantity batch production •Minimizing the set-up time,

TPM
achieved
•“One-shot” acceptable quality product

Severe human resources shortage •Production with zero inventory

(difficulty of hiring capable people)

•Automation
 Shortening the working hours •Reduce manpower
 Aging society, highly educated people •Unmanned plant operation
 Avoidance of “3D jobs” (break time, night working..)

(Difficult, Dirty, Dangerous)

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TPM Pillars

Autonomous Maintenance
8 Major Pillars of TPM
( 7 Steps)

1. Autonomous Maintenance

2. Focused Improvement Step1 > Perform Initial cleaning

Step2 > Find Contamination Sources

3. Planned Maintenance
& Inaccessible places ( Hard to access area)
4. Education & Training
Step3 > Establish Cleaning & Checking Standards
5. Safety & Environment Step4 > Over All Check of Machine & Improvements

6. Office Dept Activities Step5 > Over All Process Check

Step 6 > Systematic Autonomous maintenance

7. MP & Early Management
Step 7 > Practice Autonomous maintenance
8. Quality Maintenance

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Autonomous Maintenance

What is Autonomous Maintenance?

(1) Operators should look after their own equipment

Autonomous Maintenance aims to create a scenario where all operators look after
their own equipment, carrying out routine checks, oiling and greasing, replacing
parts, doing simple repairs, spotting problems at an early stage, checking precision
and so on.
(2) Operators need to understand their equipment
Autonomous Maintenance can only be carried out by operators who are
thoroughly conversant with their equipment. An operator’s work does not begin
and end with operation: it has to embrace maintenance as well.

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Step-1.1 Initial Cleaning- Cleaning is Inspection

Initial Cleaning

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 Mention Cleaning -Inspection Issues in This Format , Plan for Improvement &
Step 1.2 Close issues & mention photo After Improvement for each Point

Check Points PLAN PENDING DONE

○ Thorough cleaning of dust and dirt focused on the main unit of equipment
○ Removal of defect area of equipment by checking
○ Removal of unnecessary supply/demand part Month- Apr~May’15

Sr.No. Before Photo After Photo Issue /Concern Action Resp W1 W2 W3 W4 W1

Oil Leakage from  All Leakage cleaned &

PM
1     hydraulic pipe of stopped by changing          
clamping side puncher hydraulic pipe

 All loose pipe re tight,

 Loose water pipes &
clean and stop water
2     Joints causes water PM          
leakage by changing
leakage
nipples & pipes

Unwanted Tools &  All unwanted tools &

SM
3     Material present on material to be shift at it          
machine fix location

 Open main water line

Open water line
repeatedly damaged by
4     covered and protected SM          
hot material & sharp
with metallic tray
edge

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Step-1.1 Initial Cleaning- Cleaning is Inspection

Machine Cleaning Control Switch Broken Machine Cover Loose

Paint on Bolts , Thread Parts MCB Panel Open Loose Wire Inside Panel

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Step 2.1 Cleaning Tools Hard to Access Areas

• Identify Areas/ Locations which are not easy to clean, Hard to access, ( Hidden Areas )
• Define tools for cleaning these areas , ( customize tools as per requirements)
• Keep all these tools on Shadow Board . Use these tools for Cleaning / Inspection
Machine Cleaning & Tightening Tools
4ft

3 Ft

1.5 mtr

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Step 2.1 Cleaning Tools Hard to Access Areas

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Step 2.1 Cleaning Tools Hard to Access Areas

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Step 2.1 Cleaning Tools Hard to Access Areas
Step 2.1 Cleaning Tools Hard to Access Areas
Step 2.1 Cleaning Tools Hard to Access Areas
Step-3 Establish Cleaning & Checking Standards

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Step-3 Establish Cleaning & Checking Standards
Step-3.1 My Machine – Inspection Standard
Machine Construction Operator Kishan Operator Vijay Division Contents

Mob 9911665472 Tel. 8588816978 Name of Machine Vacuum Forming-1

Production Company COMI

1 Date of Installation 2009.09.01

1 　Use Department Production
1 3 Pic. Pic.
2 　One Point Liner Formation Good

1
0
Revision
Cleaning/Check/oil-feeding/Safety Standard-Document 2015Y 4M 28D
Date
Cleaning/Check/oil-feeding/Safety Check Point No Cleaning Point Cleaning standards
Cleaning
Tool
Time Period Time
method (min) D W M On Off
1 Hydraulic filter Be clean air wash Cloth 10 ● ●
2 vacuum pump Be clean air wash Cloth 10 ● ●

4 all motors Be clean air wash air gun,Cloth 10 ● ●

6 7 4 Cleaning 5

6
sensors

Machine floor
Be clean

No leak & pollution

Blowing,
wash
wash
air gun,Cloth

Broom,
10

20 ●
● ●

●
wiper
Blowing, Air_gun,Clot
7 Machine Panel Be clean 10 ● ●
wash h
Brush &
Thermulator Brush,chemic
8 To be open and clean chemical 60 ●
heater al
wash
Check Time Period Time
No Check Point Check standards Tool
method (min) D W M On Off
abnormal noise & hearing,touc
1 Motors - 1 ● ●
vibration h
control,nake
2 FRL No leak & pollution /level level 1 ● ●
d eye
Within
3 vacuum oil No leak & pollution /level gauge 1 ● ●
Check gauge

9 1 4

5
Air pressure

Vacuum Gauge
Air 4~6 kg/㎠

min 650-600mm/hg
control,nake
d eye
control,nake
gauge

gauge
1

1
●

●
●

●
d eye

3 6

7
transport gap

Hydraulic power
655 mm

level indication
measuring

level
measuring
tape
level
1

1
●

●
●

●
pack
Feeding standards Feeding Time Period Time
No Feeding Point Tool
Type Quantity method (min) D W M On Off

oil-feeding vacuum oil Rarus-427 20 L Refill by keap 10 ● ●

Hydraulic power
BPCL-68 20 L Refill by keap 10 ●
pack
Lubrication oil castrol 200 gm Refill oil kuppi 10 ●
Safety Time Period Time
No Safety Point Safety standards check Tool
(min) D W M On Off
method

c a Safety
a

b
Emergency
Switch
Safety Device
Easy operation

Not brokend
operation
Check
operation
Check
-

-
1

1
●

●
●

door safety limit Easy operation

C 1 ● ●
switch operation Check
operation
d safety sensors Easy operation 10 ● ●
Check

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Step-3.2 Visual Standard on Machine

Oiling/Greasing Valve Direction Air Flow Marking

Visual Display :Direction

Motor Direction Min-Max Marking Flow Marking & Pipe color

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Step-3.2 Visual Standard on Machine

Panel Responsibility Product Direction (Big M/C) Safety Instruction

Safety Guard Safety Instruction Safety Sensor Check

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Step-3.2 Visual Controls
Step-3.2 Visual Controls
Step-3.2 Visual Standard on Machine

Moving Direction Marking Moving Direction Marking IN & OUT Flow marking

Direction Marking
Direction Marking

Direction Marking
Pipeline Color Standard

PICTORIAL EXPLANATION

1. Pipe Color Standard :-

a) Direction of Flow should be marked with Arrow. (Refer Arrow
Standard)

2. Measurements :-
a) Distance between 2 Color Bands = 5 Meter.
b) Band Width : Size of Pipe (OD) and Width of Band should be
same in mm.

Visual
3. General Standard :-
a) For All Insulated Pipelines Color Code on Insulation is not
Required, Only Arrow with Name of Fluid Mentioned on that

Standards arrow is Reqd. with Defined Color Code on Arrow e.g.

HOT
WATER
b) Hydraulic Pipes are not Covered under Color Code.
c) Direction Arrow reqd. to be marked /pasted on all Pipelines as per
Arrow Standard.
d) Paint make and their part no will be provided separately as per
these RAL No. Standard for Paint Purchase.

1/6

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Step- 4 Over All Check of Machine & Improvements

Preparation for General Inspection Training

 Select general inspection items
1. Determine what to be taught to operate the equipment and what to inspect
2. Consider the equipment’s design specifications and the frequency of problems
3. Always include general purpose equipment such as valves, pumps
4. Select equipment’s basic functional elements such as nut, bolts etc.
 Prepare materials for general inspection training
Step 4: Perform General Equipment Inspection
Objective :Define general equipment inspection guidelines to enhance Operators skill
 Prepare materials for general inspection training
1. Detail all items that operator need to check through their five senses and summarize these
2. Decide what operators need to learn
3. Make general inspection manual
4. Manual contents –basic functions and structure of equipment, its components with names
& functions, pass fail criteria, inspection procedure and action for abnormalities
5. Prepare cutway models, easy to read wall charts, and actual samples of worn shaft, dirty oil
etc.
 Draft general inspection training schedule
1. Prepare schedule in consultation with production managers
 TPM Tag Flow
Step-4.1

Tag Management How To ?

Operator : Part
1
 Abnormality → TPM Tag
 Unique tag no. Machine wise
 Tear half & tag with machine
 Cleaning Is Inspection  Put lower half at drop in box
 Issue Identification PM Member :Part
2
 Collect tag lower half
 Supervisor assign work
 Technician Check tag issue
 Issue closure

TPM Tag to be used for Major issues , which needs PE ( Maintenance )

Support

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 TPM Tag Flow
Step-4.2

Part 1 Operator

Step 2 Step 3
Step 1 Step 4

Issue Observation Fill Tag Tear Tag Attach to M/C

Abc xxxxx

Step 6 Step 5
TPM Stand Place in Stand
Operator

 Operator is Machine
TPM Stand .
Owner
 Abc xx
Cleaning Is Inspection
 Identify Abnormality
TPM Tag – Step 1 ~ Step 6 to be filled by Operator

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 TPM Tag Flow
Step-4.3
Part 2 PM Member

Step 1 Step 2 Step 3 Step 4

Tag Collection Work Allocation Check Issue Counter Action
by PM Member

Step 5
Step 6
Card Submission Action Report
 Tag Collection
 Defect Tag Management
 Issue Rectification

TPM Tag – Step 1 ~ Step 6 to be done by PM

Member
PM : Preventive
Maintenance

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THANKS