Welcome to our PresentationCONTENTS OF TPMINTRODUCTION TO TPMTPM ?Why TPM ?History of TPMSlide 7Similarities & Differences between TQM & TPMSimilaritiesDifferencesTypes of MaintenanceSlide 12Slide 13Steps in introduction of TPM in a organization – Preparatory Stage (Step A)Step A - Preparatory StageStep B – Introduction StageSlide 17STEP C – IMPLEMENTATION STAGEPILLARS OF TPMPILLAR 1 – 5SSlide 21PILLAR 2: AUTONOMOUS MAINTENANCEPILLAR 3: Kaizen (Kai=change Zen=good)PILLAR 4: PLANNED MAINTENANCEPILLAR 5: QUALITY MAINTENANCEPILLAR 6: TRAININGPILLAR 7: OFFICE TPMPILLAR 8: SAFETY, HEALTH & ENVIRONMENTGOALS OF TPMTPM TARGETSOverall Plant Efficiency (OPE)Overall Equipment Efficiency (OEE)6 major losses measured by TPMOEE ModelAvailabilityPerformance EfficiencyRate of Quality ProductExample of OEE CalculationOEE Calculation – Contd.DIRECT BENEFITS OF TPMINDIRECT BENEFITS OF TPMDIFFICULTIES FACED IN TPM IMPLEMENTATIONCONCLUSIONReference ListWelcome to our PresentationTotal Productive Maintenance (TPM)Presented by:Rashmita TripathyKristen HammelCONTENTS OF TPMIntroductionWhy TPM?History of TPMSimilarities and differences between TQM and TPMTypes of maintenanceSteps in introduction of TPM in an organizationPillars of TPMGoals of TPMTPM targetsExample of OEE CalculationBenefits of implementing a TPM systemDifficulties faced in TPM implementationConclusionReference listINTRODUCTION TO TPMTPM is keeping the plant and equipment at its highest level through cooperation of all areas of the organization.The first part of TPM involves breaking down the barriers between maintenance and production personnel so they are working together.A common objective of TPM is peak performance or total productivity.TPM ?Total Productive Maintenance can be considered the medical science of machinesThe idea behind TPM is to markedly increase production while at the same time increasing employee morale and job satisfaction.TPM brings maintenance into focus as a necessary and vitally important part of the business.Down time for maintenance is scheduled as a part of the manufacturing day and, in some cases, as integral part of the manufacturing process.The goal is to hold emergency and unscheduled maintenance to a minimum.Why TPM ?Avoid wastage in a quickly changing economic environment.Producing goods without reducing product quality.Reduce cost.Produce a low batch quantity at the earliest possible time.Goods sent to the customers must be non-defective.History of TPMTPM is a innovative Japanese concept, and the origin of TPM can be traced back to 1951, when preventive maintenance was introduced in Japan.However the concept of preventive maintenance was taken from the United States.Nippondenso was the 1st company to introduce plant wide preventive maintenance in 1960.History of TPMPreventive maintenance is the concept wherein operators produced goods using machines and the main group was dedicated with work of maintaining those machines.However maintenance became a problem as more personnel were required, so management decided that the routine maintenance of equipment would be carried out by the operators (this is autonomous maintenance, which is one of the features of TPM).Nippondenso which already followed preventive maintenance also added Autonomous maintenance done by production operators. This lead to maintenance prevention, thus preventive maintenance along with maintenance prevention and maintainability improvement gave birth to Productive Maintenance.Similarities & Differences between TQM & TPMThe TPM program closely resembles the popular TQM program. Many of the tools such as employee empowerment, benchmarking, documentation, etc. used in TQM are used to implement and optimize TPM.SimilaritiesTotal commitment to the program by upper level management is required in both programs.Employees must be empowered to initiate corrective action.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.DifferencesTQM’s objective is Quality (Output and effects) and TPM’s objective is Equipment (Input and cause).TQM obtains goals by systematizing the management and it is software oriented and TPM obtains goals by employee participation and it is hardware oriented.TQM’s target is quality for PPM and TPM’s target is elimination of losses and wastes.Types of MaintenanceBreakdown maintenance: it means that people wait until equipment fails and repair it. Such a thing could be used when the equipment failure does not significantly affect the operation or production or generate any significant loss other than repair cost.Preventive maintenance: It is a daily maintenance ( cleaning, inspection, oiling and re-tightening ), design to retain the healthy condition of equipment and prevent failure through the prevention of deterioration, periodic inspection or equipment condition diagnosis, to measure deterioration. It is further divided into periodic maintenance and predictive maintenance. Just like human life is extended by preventive medicine, the equipment service life can be prolonged by doing preventive maintenance.Types of MaintenancePeriodic maintenance: Time based maintenance consists of periodically inspecting, servicing and cleaning equipment and replacing parts to prevent sudden failure and process problems. Predictive maintenance: This is a method in which the service life of important part is predicted based on inspection or diagnosis, in order to use the parts to the limit of their service life. Compared to periodic maintenance, predictive maintenance is condition based maintenance. It manages trend values, by measuring and analyzing data about deterioration and employs a surveillance system, designed to monitor conditions through an on-line system.Types of MaintenanceCorrective maintenance: It improves equipment and its components so that preventive maintenance can be carried out reliably. Equipment with design weakness must be redesigned to improve reliability or improving maintainability.Maintenance prevention: It indicates the design of a new equipment. Weakness of current machines are sufficiently studied ( on site information leading to failure prevention, easier maintenance and prevents of defects, safety and ease of manufacturing ) and are incorporated before commissioning a new equipment.Steps in introduction of TPM in a organization – Preparatory
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