Nothing Special   »   [go: up one dir, main page]
Scribd Logo
Upload

Welcome to Scribd!

  • 16 views

    TPM-Presentation Modified

    Uploaded by

    mathan.k
    This document provides an overview of total productive maintenance (TPM). It defines TPM and its objectives to maximize equipment effectiveness through employee participation and a focus on eliminating losses. The document outlines the eight pillars of TPM implementation and lists the benefits, such as increased productivity, reduced costs and defects, and an improved work environment. TPM aims to transform plant culture and raise employee skills and knowledge through collaborative improvement efforts.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd

    TPM-Presentation Modified

    Uploaded by

    mathan.k
    16 views33 pages
    This document provides an overview of total productive maintenance (TPM). It defines TPM and its objectives to maximize equipment effectiveness through employee participation and a focus on eliminating losses. The document outlines the eight pillars of TPM implementation and lists the benefits, such as increased productivity, reduced costs and defects, and an improved work environment. TPM aims to transform plant culture and raise employee skills and knowledge through collaborative improvement efforts.

    Original Description:

    Copyright

    © © All Rights Reserved

    Available Formats

    PPTX, PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    This document provides an overview of total productive maintenance (TPM). It defines TPM and its objectives to maximize equipment effectiveness through employee participation and a focus on eliminating losses. The document outlines the eight pillars of TPM implementation and lists the benefits, such as increased productivity, reduced costs and defects, and an improved work environment. TPM aims to transform plant culture and raise employee skills and knowledge through collaborative improvement efforts.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    16 views33 pages

    TPM-Presentation Modified

    Uploaded by

    mathan.k
    This document provides an overview of total productive maintenance (TPM). It defines TPM and its objectives to maximize equipment effectiveness through employee participation and a focus on eliminating losses. The document outlines the eight pillars of TPM implementation and lists the benefits, such as increased productivity, reduced costs and defects, and an improved work environment. TPM aims to transform plant culture and raise employee skills and knowledge through collaborative improvement efforts.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 33

    1

    Welcome
     What is maintenance and their types
     What is TPM
     Why TPM need
     TPM History
     TPM Objectives
     TPM targets
     Similarity and difference between TPM and TQM
     Pillars of TPM
     Why is TPM so popular and important
     Company checklist
     Benefits of TPM
     Losses of TPM
     Conclusion
    3
    What is Maintenance?

    The Management,control,execution and


    quality assurance of activities
    which ensure the achievement of
    optimum availability and
    performance of a plant in order to
    meet business objectives.

    4
    Types Of Maintenance :

    Preventive Maintenance
    Predictive Maintenance

    Scheduled Maintenance

    Breakdown Maintenance

    5
    T: TOTAL

     Participation of all Employees.


     Include all Departments, equipment and
    process.
    operation,

    P: PRODUCTIVE

     Pursue the maximization of efficiency of the


    system
    production
    by making all loses zero.
     Zero accidents Zero defects Zero breakdowns.

    M: MAINTENANCE

     To improve the efficiency of the equipment.


     Maintenance means the entire life cycle of the production
    system.
    It is a Japanese approach for
     Creating company culture for maximum efficiency
     Striving to prevent losses with minimum cost
     Zero breakdowns and failures, Zero accident,
    and Zero defects etc.
     The essence of team work (small group activity) focused
    on condition and performance of facilities to achieve zero loss for
    improvement
     Involvement of all people from top management to
    operator

    7
     TPM first introduced in Japan 20 years ago and rigorously
    been applied in past 10 years
    • TPM planning & implementation in Japanese factories
    supported by JIPM (Japan Institute of Plant Maintenance)
    • Awarded yearly prizes to various industries:
     Automotive
     Metals
     Chemicals
     Rubber
     Food
     Glass etc.

    8
     Initially implemented in
    high-to-medium volume production areas

     Later successfully applied in:


     Low-volume production

     High-to-low volume assembly

     Development areas

     Whole range of industry

    9
    Avoid wastage in a quickly changing economic
    environment.
    Producing goods without reducing product
    quality.
    Reduce cost.

     Goods send to the customers must be non


    defective.

    1
    0
    1. Increase production while, at the same time, increasing
    employee morale and job satisfaction.
    2. Hold emergency & unscheduled maintenance to a
    minimum.
    3. To provide the safe and good working environment to the
    worker.
    4. Achieve Zero Defects, Zero Breakdown and Zero
    accidents
    in all functional areas of the organization.
    5. Involve people in all levels of organization.
    6. Form different teams to reduce defects and Self
    Maintenance.
     Toprovide the safe and good working
    environment to the worker.

    “If you focus on result you


    will never change.
    If you focus on change
    you will get Result.”

    11
    1. PRODUCTION
    I). Obtain Minimum 80% Overall Production Efficiency
    ii) Obtain Minimum 90% Overall Equipment Effectiveness
    iii) Run the Machine during lunchtime

    2. QUALITY
    Operate in a manner, so that there are no customer complaint

    3. COST
    Reduce the manufacturing cost as much as possible

    4. DELIVERY
    Achieve 100% success in delivering the goods as required by the
    customer

    5. SAFETY
    Maintain an accident free environment

    6. MULTYTASK
    Develop multiskilled & flexible workers.
     Total commitment of upper level management.
     Employees must be empowered to initiate corrective action.

    Category TQM TPM


    Quality ( Output and Equipment ( Input and
    Object
    effects ) cause )

    Systematize the Employees


    Mains of
    management. It is participation and it is
    attaining goal
    software hardware oriented
    oriented
    Elimination of losses
    Targe Quality for PPM
    and wastes.
    t
    14
    PILLAR 1 - Autonomous
     A collaborative team activity involving production,
    Maintenance
    maintenance, and engineering
     Maintaining Basic conditions on shop floor & in Machines.
     All over participation through TPM Circles.
     An approach that
     Develops operating and maintenance skills
     Strengthens communication and cooperation

     PILLAR 2 - Focused Improvement


     Improvement on every one’s activity.
     Improvement is to eliminate Production losses and cost
    reduction.
     Improvement in Reliability, Maintainability, and cost.
    PILLAR 3 - Planned Maintenance

    • Logical analysis “Real causes for real counter measures”.


    • Focus on Prevention.
    • It is aimed to have trouble free machines and equipments
    producing defect free products for total customer
    satisfaction. Example: Preventive Maintenance, Breakdown
    Maintenance, etc.,

    17
    PILLAR 4 - Quality Maintenance

    • Developing perfect machine for perfect Quality.


    • Eliminating In – Process defects and custom
    complaints.

    Policy :
    • Defect free conditions and control of
    equipments.
    • QM activities to support quality assurance.
    • Focus of prevention of defects at source
    • Effective implementation of operator
    quality assurance

    18
    PILLAR 5 - Education & Training

    • Skills development for uniformity of work practices on machines.


    • Skills for Zero defects, Zero breakdowns & Zero accidents.
    • Multi Skilled employees in all departments

    Steps in Educating and training activities :

    • Setting policies and priorities and checking present status of


    education and training.
    • Establish of training system for operation and maintenance skill
    up gradation.
    • Training the employees for upgrading the operation and
    maintenance skills.
    • Preparation of training calendar.
    • Evaluation of activities and study of future approach.

    19
    PILLAR 6 - Development Management

    • Developing machines for “high equipment


    effectiveness”.
    • Quick process for developing new
    products. Example: KAIZEN

    Kaizen Policy :
    • Relentless pursuit to achieve cost reduction targets in
    all resources.
    • Relentless pursuit to improve over all plant
    equipment effectiveness.
    • Extensive use of PM analysis as a tool for eliminating
    losses.
    • Focus of easy handling of operator

    20
    PILLAR 7 - Safety, Health & Environment

    • Zero accidents and Zero hazards at works.


    • Zero Pollution at Plant and Environment
    PILLAR 8 - Office TPM
    Office TPM should be started after activating from other pillars of
    TPM. Office TPM must be flowed to improve productivity,
    efficiency in the administrative function and identify eliminate
    losses. This includes analyzing process and procedure towards
    increased office automation. Office TPM covers twelve major
    losses. These are:
    1. Processing loss
    2. Cost loss including in areas such as procurement, accounts
    marketing leading to high inventories.
    3. Communication loss.
    4. Idle loss.
    5. Set-up loss.
    6. Accuracy loss
    7. Office equipment breakdown.
    20
    8. Communication channel breakdown.
    22
    Three main reasons:

    1. It guarantees dramatic results (Significant


    tangible results)
     Reduce equipment breakdowns
     Minimize idle time and minor stops
     Less quality defects and claims
     Increase productivity
     Reduce manpower and cost
     Lower inventory
     Reduce accidents

    23
    2. Visibly transform the
    workplace (plant
    environment)
     Through TPM, a filthy, rusty plant covered in oil
    and grease, leaking fluids and spilt powders can
    be reborn as a pleasant and safe working
    environment
     Customers and other visitors are impressed by
    the
    change
     Confidence on plant’s product increases

    24
    3. Raises the level of workers knowledge and
    skills

    As TPM activities begin to yield above


    concrete results, it helps:
     The workers to become motivated
     Involvement increases

     Improvement suggestions proliferate

     People begin to think of TPM as part of


    the job

    25
    26
    27
    28
    Direct Benefits of TPM Indirect Benefits of TPM
    1. Increase Productivity 1. Higher confidence level
    and Overall Plant among the workers
    Efficiency by 1.5 to 2 2. Keep the work place
    times clean, neat and
    2. Rectify customers attractive
    complaints 3. Favorable change in the
    3. Reduce attitude of the
    manufacturing operators
    cost by 4. Achieve goals by
    ….percent working
    4. Satisfy the customers as Team
    needs by 100% 5. Share knowledge and
    5. Reduce accidents experience
    30
    • Breakdown losses
    • Setup and adjustment losses
    • Idling and minor stoppage losses
    • Speed losses
    • Quality defects and rework losses
    • Start-up/yield losses

    31
    TPM is a Lean tool for Quality and Productivity
    Today, with competition in industry at an all time high, TPM may be the only thing
    that stands between success and total failure for some companies. It has been
    proven to be a program that works. Employees must be educated and convinced that
    TPM is not just another "program of the month" and that management is totally
    committed to the program and the extended time frame necessary for full
    implementation. If everyone involved in a TPM program does his or her part, an
    unusually high rate of return compared to resources invested may be expected.

    • TPM may be the only thing that stands between success and total failure for
    some companies
    • It can be adapted to work not only in industrial plants, but in
    construction, building maintenance, transportation, and in a variety of
    other situations.
    • Easy to operation, Improvement the availability and productivity, make 32
    operation and area safer.
    33

    You might also like