Harjit Presentation

8/8/2019 Harjit Presentation

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SEMINAR SEMINAR

TOTAL PRODUCTIVE MAINTENANCE INTOTAL PRODUCTIVE MAINTENANCE INMANUFACTURING INDUSTRIESMANUFACTURING INDUSTRIES

Presented byPresented by Harjit Singh MangatHarjit Singh Mangat

M-Tech ( Production Engg. )M-Tech ( Production Engg. )

Roll No. PE-603Roll No. PE-603


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OVERVIEWOVERVIEW

NEED FOR TPMNEED FOR TPM

TECHNIQUES IN TPMTECHNIQUES IN TPM

MAINTENANCE CONCEPTMAINTENANCE CONCEPT

TPM-DEFINATIONTPM-DEFINATION

WHAT DOES TPM MEANSWHAT DOES TPM MEANS

EIGHT STRATEGIES OF TPMEIGHT STRATEGIES OF TPM

COMPONENTS OF TPM COMPONENTS OF TPM

CHANGE IN ATTITUDE FROMCHANGE IN ATTITUDE FROM

USE OF 5Ss IN TPMUSE OF 5Ss IN TPM

OUTCOME OF 5SsOUTCOME OF 5Ss

TPM & 5Ss FOCUSES ONTPM & 5Ss FOCUSES ON

IMPLEMENTATION TPMIMPLEMENTATION TPM

LEVELS OF TPMLEVELS OF TPM

BENEFITS OF TPMBENEFITS OF TPM


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THE NEED FOR TPM

Think of productive equipment as our cars ortelephones

They are ready to go when we need them They need not run all the time to be productive

For this concept to function properly Machines

Must be ready when we need them Must be shut down in such a fashion as to

be ready the next time


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TECHNIQUES IN TPMTECHNIQUES IN TPM Just-in-Time (JIT)Just-in-Time

(JIT) - let only the system that- let only the system that

needs parts get them, and only in the quantityneeds parts get them, and only in the quantityneeded. needed.

Poka yokePoka

yoke -- Inhibits defects occurring at source & Inhibits defects occurring at source & Correcting divergences causing defects.Correcting divergences causing defects.

Single Minute Exchange of Die (SMED)

Single Minute Exchange of Die (SMED)Setup & Change-over time less than 10 minutesSetup & Change-over time less than 10 minutes

Speed

Speed - Speed means the rate at which a product is- Speed means the rate at which a product ismanufactured.manufactured.


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MAINTENANCE CONCEPTMAINTENANCE CONCEPT

Undertaken to preserve proper functioning of aUndertaken to preserve proper functioning of aphysical system, so that it will continue to do what itphysical system, so that it will continue to do what itwas designed to do.was designed to do.

Function and performance characteristicsFunction and performance characteristicshave-have-

Output, unit costs and effectiveness of using energy.Output, unit costs and effectiveness of using energy.

Protection of employees, end-product qualityProtection of employees, end-product quality


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Failures attract attention because they affectsFailures attract attention because they affects

OutputOutput

Safety and environmental healthSafety and environmental health

Quality of end productQuality of end product

Customer serviceCustomer service

Competitiveness and unit costs.Competitiveness and unit costs.

Severity and frequency of failureSeverity and frequency of failure dictate whichdictate whichfailure-management technique is worth applying.failure-management technique is worth applying.


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TOTAL PRODUCTIVE MAINTENANCETOTAL PRODUCTIVE MAINTENANCE TPMTPM involves operational and maintenance staff involves operational and maintenance staff

working together as a team toworking together as a team to

Reduce wastage & Minimizes downtimeReduce wastage & Minimizes downtime

Improve end product quality.Improve end product quality.

Main objective is to achieveMain objective is to achieve

Zero breakdowns, Zero defects,Zero breakdowns, Zero defects, Zero error, zerowork-related accident and zero loss .


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WHAT DOES TPM MEANSWHAT DOES TPM MEANS

Total = EveryoneTotal = EveryoneProductive = No wasted activityProductive = No wasted activityMaintenance = As new activityMaintenance = As new activity

Main issuesMain issues are: People, Equipment, Methods,are: People, Equipment, Methods,Losses/Wastes, Performance measurement.Losses/Wastes, Performance measurement.

People issues -People issues - Attitude, Team working, Attitude, Team working,

Training, ManagingTraining, Managing

Equipment issues-Equipment issues- Condition, Layout, DesignCondition, Layout, Design ,,

SparesSpares


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Method issues-Method issues- Cleaning, Storage, AccuracyCleaning, Storage, Accuracy

Loss issues-Loss issues- Wasted time, Wasted effort,Wasted time, Wasted effort,Wasted MaterialsWasted Materials

Six major losses-Six major losses- Equipment failureEquipment failure Set up and ChangeoversSet up and Changeovers Start-upsStart-ups Minor StopsMinor Stops

SpeedsSpeeds Defects/rework Defects/rework

Performance measures-Performance measures- What data you collect;What data you collect;

How you collect data; How you use dataHow you collect data; How you use data


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EIGHT STRATEGIES OF TPM

TPM

F O C U S E D

I M P R O V E M E N T S

A U

T O N O M O U S

M A I N T E N A N C E

T E C H N I C A L

T R A I N I N G

O

F F I C E T P M

P L A N N E D


Q U A L I T Y


EIGHT STRATEGIES OF TPM

S A F E T Y

& E N V I R O N M E N T

M A N A G E M E N T

E A R L Y E Q U I P M E N T

M A N A G E M E N T


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MAIN COMPONENTS OF TPMMAIN COMPONENTS OF TPM

Overall equipment-effectivenessOverall equipment-effectiveness

OEE= Availability * Product rate* QualityOEE= Availability * Product rate* Quality

Availability Availability = Actual running time/Ideal time= Actual running time/Ideal time

Product rateProduct rate =Actual output/Actual running=Actual output/Actual runningtime *MPR time *MPR

QualityQuality = Good output/Actual output= Good output/Actual output


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OVERALL EQUIPMENTEFFECTIVENESS

AVAILABILITY PERFORMANCE

RATE

QUALITY RATE

BREAKDOWN LOSS

ADJUSTMENT LOSS

REDUCED SPEED LOSS

SETUP & ADJUSTMENTLOSS

QUALITY DEFECT

REWORK & STARTUPLOSS


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Autonomous-operator maintenance Autonomous-operator maintenance

It looks into achieving a high degree of It looks into achieving a high degree of

CleanlinessCleanliness

Excellent lubricationExcellent lubricationProper fastening to prevent machine breakdown.Proper fastening to prevent machine breakdown.

Companys small group activities,Companys small group activities, throughoutthroughoutentire organizationentire organization.


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MUST CHANGE IN ATTITUDE FROMMUST CHANGE IN ATTITUDE FROM

Its not my job Its not my job

They dont so why should we They dont so why should we

Dont tell me Dont tell me

Its nothing to do with me Its nothing to do with me

Just get it going Just get it going

Itll do Itll do


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USE OF 5Ss IN TPMUSE OF 5Ss IN TPM 11 stst S (Shift)S (Shift) -Shift unnecessary items to store or-Shift unnecessary items to store or

skip them if obsolete (no use anymore)skip them if obsolete (no use anymore) 22 ndnd S (Shine)-S (Shine)- Sweep and shine the workplaceSweep and shine the workplace

33 rdrd S (Sort)S (Sort) - Secure a place for everything and- Secure a place for everything andstore everything in its place i.e tools, consumablesstore everything in its place i.e tools, consumables

44thth

S (Standardize)-S (Standardize)- Show that you can doShow that you can doeverything in a standardized wayeverything in a standardized way

55 thth S (Stick to rules)-S (Stick to rules)- Seek to eliminate rootSeek to eliminate root

causes of problemscauses of problems


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OUTCOME OF 5SsOUTCOME OF 5Ss Greater efficiency & operator involvementGreater efficiency & operator involvement

Reduced failures & defectsReduced failures & defects

Less accidentsLess accidents

Increases Overall plants productivityIncreases Overall plants productivity

Improves Rate of throughputImproves Rate of throughput

Better End-product quality and servicesBetter End-product quality and services


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TPM AND 5Ss FOCUSES ON-TPM AND 5Ss FOCUSES ON- Cleaning and restoring conditionCleaning and restoring condition

Monitoring and inspectingMonitoring and inspecting

Lubricating and repairingLubricating and repairing

Improving and organizingImproving and organizing

TrainingTraining

MeasuringMeasuring


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IMPLEMENTATION - TPMIMPLEMENTATION - TPM Operators should know well

What maintenance tasks are theirs. What are appropriate for skilled crew.

TPM starts with 5Ss

Cleaning and organizing workplace helps team touncover problems

Making problems visible is the first step of improvement


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LEVELS IN TPMLEVELS IN TPM

Entire workforceEntire workforce must first be convinced that top-must first be convinced that top-level management is committed to the programme.level management is committed to the programme.

Senior management teamSenior management team sets company-wide PMsets company-wide PMpolicies.policies.

Middle managementMiddle management oversees the departmentaloversees the departmentalpolices.polices.

Shop-floor managementShop-floor management sets the PM goalssets the PM goalsaccording to team groups activities.according to team groups activities.


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TPM coordinatorTPM coordinator is hired whose responsibility is tois hired whose responsibility is tomake TPM understandable to the workforce.make TPM understandable to the workforce.

After coordinator is convinced a After coordinator is convinced a study and actionstudy and actionteamteam is formed.is formed.

Operation & maintenance staff, supervisors,Operation & maintenance staff, supervisors,schedulers and top managementschedulers and top management -all be in team.-all be in team.

Action teams Action teams have responsibility for assigning smallhave responsibility for assigning smallprojects for problems & indicating remedial processesprojects for problems & indicating remedial processes


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BENEFITSBENEFITS Use cross-functional teams consisting of operators,Use cross-functional teams consisting of operators,

maintainers, engineers and managers.maintainers, engineers and managers. Improve individual employee and equipmentImprove individual employee and equipment

performances.performances.

Improved proceduresImproved procedures forfor -- change-over and set-upschange-over and set-ups

Increased enthusiasmIncreased enthusiasm

Increases involvement of the workforceIncreases involvement of the workforce

More cooperative teamwork More cooperative teamwork


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THANKSTHANKS

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