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8/14/2019 PI & SS-GR-1
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PRESENTED BY-
ABHILASH DAS (ROLL NO-01)
AJATASATRU ROUT(ROLL N0-02)SHIBA PRASAD DAS(ROLL NO-46)
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CONCEPT
“Unless the machine and equipment are in
good condition with high process
capabilities, one cannot expect defect free
production.”
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TQM
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TQM: A “Buzzword” Losing Popularity
• For many companies, the term TQM isassociated with corporate programs (mid 1980s~ early 1990s) aimed at implementing employeeteams and statistical process control.
• Unfortunately, many companies weredissatisfied with the perceived results of theseprograms, concluding TQM does not work.
Question: Why were they dissatisfied?Were they justified?
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TQM
• Total - Made up of the whole• Quality - degree of excellence a product or
service provides
• Management - Act, art or manner of planning, controlling, directing,….
Therefore, TQM is the art of managingTherefore, TQM is the art of managing
the whole to achieve excellencethe whole to achieve excellence.
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What does TQM mean? Total Quality Management means that the
organization's culture is defined by and
supports the constant attainment of
customer satisfaction through an
integrated system of tools, techniques,
and training.
This involves the continuous improvement
of organizational processes, resulting in
high quality products and services
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The three aspects of TQM
CountingTools, techniques, and training in
their use for analyzing,
understanding, and solving quality
problems
CustomersQuality for the customer as a
driving force and central concern
CultureShared values and beliefs, expressed
by leaders, that define and support
quality.
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The TQM System
Total Quality Management
CustomerFocus
ProcessImprovement
TotalInvolvement
Leadership
Education and Training Supportive structureCommunications Reward and recognitionMeasurement
ContinuousImprovement
Objective
Principles
Elements
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TPM
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Origins of TPM
• Dr. Deming introduced statistical analysis and used the
resulting data to control quality during manufacturing
(TQM)
• Some general concepts of TQM did not work well in the
maintenance environment
• The need to go further than preventive maintenance was
quickly recognized by those companies who were
committed to TQM
• Maintenance became an integral part of TQM in the
early 90’s
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Journey of Maintenance
Management(Breakdown maintenance=BM)
(Profitable preventive maintenancePPM =BM+PM)
(Productive maintenance=BM+PM+MI+PM)
(Total productive maintenance,
TPM =BM+PM+MI+PM+CI)
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Four Maintenance Models
• Corrective Maintenance
• Preventive Maintenance
• Predictive Maintenance• Total Productive Maintenance
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What is TPM ?
• To set a goal to maximize equipment efficiency (overall
efficiency).
• By establishing a total system for TPM for the entire life of
equipment.
• Participation by all departments at all levels, including
equipment planning, operating and maintenance
departments.
• Involving/motivating all personnel including top personnel to
first-line operators.
• For promoting TPM by motivation management, namely, by
autonomous small-group activities/voluntary activities.
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15
PRINCIPLESPRINCIPLES
In its broadest sense, TPM is based on three sets of
principles1. Maintenance Engineering ; Seeks to manage the
equipment life cycle, from strategic asset planning,
through design and construction, to operation,
maintenance, and disposal. Several techniques
characterize the proactive nature of maintenance
engineering including:
2. Preventive (or planned) maintenance: Planned and
scheduled maintenance activities to find and correct
problems that could lead to failure3. Predictive and condition-based maintenance:
Reducing fixed-time maintenance and relying on the
condition of equipment to determine maintenance
activity
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Eight major pillars of TPM
A u t o n o
m o u s M a i n t e n a n c e
P l a n n e
d M a i n t e n a n c e
E q u i p m
e n t a n d p r o c e s
s i m p r o v e m e n t
E a r l y m
a n a g e m e n t o f n
e w
e q u i p m e n t
P r o c e s
s q u a l i t y m a n a g
e m e n t
T P M i n
t h e o f f i c e
Education and training
Safety and environmental management
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• Total Productive Maintenance is …
operator driven reliability:
The Operators’ Creed of TPM –
Keep it clean
Keep it lubricated
Monitor for degradation
Maintain it before production is affected
Simplify and improve it
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IMPLEMENTATION
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TQM Implementation
1. Capitalize on the current village / fatherland-likeculture to facilitate the TQM process.
Ensure that the change stays and has the desired results.
Training in the basic elements of TQM must beprovided to all employees
Involved all employees in the process. Ensures that they actually take "ownership" of the processto facilitate the success of the program.
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TPM Implementation12 steps
Preparation
Kick-off
Implementation
Announcement to introduce TPMIntroductory education campaign for the workforce
TPM Promotion (special committees)
Establish basic TPM policies and goals
Preparation and Formulation of a master plan
Develop an equipment management program
Develop a planned maintenance program
Develop an autonomous maintenance programIncrease skills of production and maintenance personnel
Perfect TPM implementation and raise TPM levelsStabilization
Develop early equipment management program
Invite customers, affiliated companies and subcontractors
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7 Visual Quality Management Tools for
TPM Problem Solving
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Some research papers
• Integrating TQM and TPM into a management
information system
– International Journal of Information Technology and
Management ( Issue: Volume 1, Numbers 2-3 /
2002 Pages: 242 – 255 ) – inderscience.metapress.com
• Relationships between implementation of TQM, JIT,
and TPM and manufacturing performance
– Journal of Operations Management (Volume 19, Issue 6,November 2001, Pages 675-694 )
– www.sciencedirect.com
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CONTD….
• Relationship between TQM and TPM implementation
factors and business performance of manufacturing
industry in Indian context – Journal: International Journal of Quality & Reliability
Management
( Volume: 22, Number: 3, Year: 2005,pp: 256-277 )
– www.emeraldinsight.com
• A Comparative Review of TQM, TPM and Related
Organizational Performance Improvement Programs – This paper appears in: Emerging Trends in Engineering and
Technology, 2008. ICETET '08. First International Conference on
Publication Date: 16-18 July 2008
On page(s): 725-730
– ieeexplore.ieee.org
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Career Opportunities in TQM &
TPM• TPM officer
• Process Improvement Manager
• Quality Consultant
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CONCLUSIONTotal Productive Maintenance (TPM) Aims at
• Zero breakdown
• MTBF (mean time between failures should be minimized)
• MTRR (mean time to repair) should be brought down by breakdown
maintenance efficiency
• Preventive maintenance should be planned and implemented
• Predictive maintenance should be planned and implemented
• Warranty of maintenance concept should be implemented
Total Quality Management (TQM) Aims at
Zero Defect: A possibility
• Move from inspection to self audit
• Followed by successive audit
• Process capability upkeep and enhancement: statistical process control (SQC)
and statistical quality control (SQC)
• 5S Housekeeping
• Total Productive maintenance (TPM)
• Zidoka and Andon: Employee empowerment and autonomation• Poka-yoke
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“Quality is a Journey,
not a Destination”