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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
M A I N T E N A N C E
Q U A L I T Y
M A I N T E N A N C E
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