Total Productive Maintenance_pnkj

8/14/2019 Total Productive Maintenance_pnkj

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TOTAL PRODUCTIVEMAINTENANCE

PRESENTED BY

KARAN PARMAR

1530/06,IEM-2

NIT KKR.


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DEFINITIONTotal Productive Maintenance

(TPM) is a maintenance programwhich involves a newly definedconcept for maintaining plantsand equipment. The goal of theTPM program is to markedly

increase production while, at thesame time, increasing employeemorale and job satisfaction.


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TYPES OFMAINTENANCE

1. Breakdown maintenance

2. Preventive maintenance

2a. Periodic maintenance ( Time basedmaintenance - TBM)

2b. Predictive maintenance

3. Corrective maintenance

4. Maintenance prevention


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LIFETIME FAILURE RATES

improper usefailure

normal failure Wearoutfailure

Failurerate

Lifetime


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ATTITUDES

Operator Maintenance

Conventional

I use I maintain &I fix

OperatorMaintenance

NEW TPM

We maintain


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AUTONOMOUS MAINTENANCE

The principal way in which production workersparticipate in TPM

Purpose

2. Helps operators learn more about theirequipment.

4. Prepares operators to be active partners withmaintenance and engineering in improvingequipment performance and reliability


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BENEFITS OF TPM FOROPERATORS & MAINTENANCE

PERSONNEL

Increased skills through additional training

Better job satisfactionMore challenging work

More involvement in solving equipment problems

Workers gets the feeling of owning of machine.

Better job security


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N OF TPM INAN

ORGANIZATIO

N


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VARIOUS STAGES :

a). PREPARATORY STAGE

b). INTRODUCTION STAGE

c). IMPLEMENTATIONd). INSTITUTIONALISING STAGE


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Pillars of

TPM


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PILLAR 1 - 5S :

Japanese TermEnglishTranslation

Equivalent 'S'term

Seiri Organisation Sort

Seiton Tidiness Systematise

Seiso Cleaning SweepSeiketsu Standardisation Standardise

Shitsuke Discipline Self - Discipline


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PILLAR 2 - JISHU HOZEN ( AUTONOMOUSMAINTENANCE ) :

This pillar is geared towardsdeveloping operators to be able totake care of small maintenance tasks,

thus freeing up the skilledmaintenance people to spend time onmore value added activity andtechnical repairs. The operators are

responsible for upkeep of theirequipment to prevent it fromdeteriorating.


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PILLAR 3 - KAIZEN :

"Kai" means change, and "Zen" means good.

This pillar aims at reducing losses in theworkplace that affect our efficiencies.


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PILLAR 4 - PLANNED MAINTENANCE :

PILLAR 4 - PLANNED MAINTENANCE :

It is aimed to have trouble free machine andequipments producing defect free productsfor total customer satisfaction . Types :-

Breakdown Maintenance

Preventive Maintenance

Corrective Maintenance

Maintenance Prevention


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PILLAR 5 - QUALITY MAINTENANCE :

QM activities is to set equipment conditionsthat preclude quality defects, based on thebasic concept of maintaining perfectequipment to maintain perfect quality of

products.


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PILLAR 6 - TRAINING :

Phase 1 : Do not know.Phase 2 : Know the theory but cannot do.Phase 3 : Can do but cannot teach(skilled)Phase 4 : Can do and also teach. (expert).


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THE PEOPLE OF SUCCESSFULTPM


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PILLAR 7 - OFFICE TPM :

Office TPM must be followed to improveproductivity, efficiency in the administrativefunctions and identify and eliminate losses.

This includes analyzing processes and

procedures towards increased officeautomation.


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PILLAR 8 - SAFETY, HEALTH ANDENVIRONMENT

Target :

Zero accident,

Zero health damage

Zero fires.


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DIRECT BENEFITS OF

TPM

OEE up by 25-65%.

Rectify customer complaints.

Reduce the manufacturing cost by 30%.

Satisfy the customers needs by 100 % . Reduce accidents.

Follow pollution control measures.


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INDIRECT BENEFITS OF

TPM

Higher confidence level among theemployees.

Keep the work place clean, neat andattractive.

Favorable change in the attitude of theoperators.

Achieve goals by working as team.

Share knowledge and experience.The workers get a feeling of owning the

machine.


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24

VIEW

MaintenanceCommitment

ost

Optimal

Total costs

Full cost ofbreakdowns

Preventivemaintenancecosts


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CONCLUSION:

Today, with competition in industry at an alltime high, TPM may be the only thing thatstands between success and total failure forsome companies.

If everyone involved in a TPM program doeshis or her part, an unusually high rate ofreturn compared to resources invested maybe expected.


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REFERENCES:

Wikipedia

Journal of Industrial Engineering

Industrial Engineering & Quality Maintenance

www.scribid.co.in www.google.com


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THANKTHANK

YOU.YOU.


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QUERIES

?????

Documents

Total Productive Maintenance_pnkj