Total Productive Mantainence

Total Productive Mantainence

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  BY:- Kanhaiya Atal (41)
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  CONTENT  Introduction  Whatis TPM?  Why TPM?  Evolution OF TPM  Benefits of Total Productive Maintenance (TPM)  Losses of Total Productive Maintenance (TPM)  Eight Pillars of Total Productive Maintenance (TPM)  Similarities and difference between TQM and TPM:  Introduction to OEE  Creating a “Best of the Best” OEE Goal  Conclusion  References
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  INTRODUCTION  Maintenance hasa far greater impact on corporate profitability than most managers are willing to consider, much less admit .  And, as the competitive environment in the world continues to increase the pace, companies are looking for new strategies to save on costs, develop employees to face future challenges and bring about a new culture at work place.
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  WHAT IS TOTALPRODUCTIVE MAINTENANCE?  T: TOTAL  Participation of all Employees.  Covers all Departments.  Cover all operation, equipment and process.  P: PRODUCTIVE  Pursue the maximization of efficiency of the production  System by making all loses zero.  Zero accidents Zero defects Zero breakdowns.  M:MAINTENANCE  Maintenance is not only to repair and maintain the machines.  To improve the efficiency of the equipment.  Maintenance covers the entire life cycle of the production system.
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  WHY TPM TPM wasintroduced to achieve the following objectives. The important ones are listed below.  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.
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  EVOLUTION OF TPM TPM descends from Japan and came into existence in the seventies.  After Dr W Edward Deming made an impact in Japan through his teaching of quality, Japanese organization felt a need for autonomous maintenance and small group activities to support the quality movement.  Today thousands of organizations all over the world are implementing TPM and about 100organisations are now doing it in India.  Nippondenso was the first company to introduce plant wide preventive maintenance in 1960
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  EIGHT PILLARS OFTOTAL PRODUCTIVE MAINTENANCE
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  BENEFITS OF TOTALPRODUCTIVE MAINTENANCE (TPM)  Productivity Improvement - Productivity is improved through fewer losses in the company.  Employee Ownership - Ownership of equipment by operators through Autonomous Maintenance.  Increased Plant Reliability.  Customer Satisfaction - TPM leads to high delivery performance and customer satisfaction.
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  LOSSES OF TOTALPRODUCTIVE MAINTENANCE (TPM)  Breakdown losses  Setup and adjustment losses  Idling and minor stoppage losses  Speed losses  Quality defects and rework losses  Strat-up/ yield losses
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  SIMILARITIES AND DIFFERENCEBETWEEN TQM AND TPM  The TPM program closely resembles the popular Total Quality Management (TQM) program. Many of the tools such as employee empowerment, benchmarking, documentation, etc. used in TQM are used to implement and optimize TPM. Following are the similarities between the two.  Total commitment to the program by upper level management is required in both programmers.
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  SIMILARITIES AND DIFFERENCEBETWEEN TQM AND TPM…
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  TYPES OF MAINTENANCE 1.Breakdown maintenance 2. Preventive maintenance (1951) 2a. Periodic maintenance (Time based maintenance - TBM) 2b. Predictive maintenance 3. Corrective maintenance (1957) 4. Maintenance prevention (1960 )
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  INTRODUCTION TO OEE OEE (Overall Equipment Effectiveness) is a metric that identifies the percentage of planned production time that is truly productive. It was developed to support TPM initiatives by accurately tracking progress towards achieving “perfect production”.  An OEE score of 100% is perfect production.  An OEE score of 85% is world class for discrete manufacturers.  An OEE score of 60% is fairly typical for discrete manufacturers.  An OEE score of 40% is not uncommon for manufacturers without TPM and/or lean programs.
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  CONCLUSION  TPM isa practical and down to earth technique aimed at maximizing the effectiveness of facility that we use within our organization.  The essence of TPM is team work, and at its very heart lies the motivation and encouragement of the people who work within the organization.  Today thousands of organizations all over the world are implementing TPM and about hundred organizations is now doing it in India.