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MKS/TPM/RKFL/01-2008
TOTAL PRODUCTIVE MAINTENANCE
Presentation byMahendra K. SHUKLA
Sr. Manager & HOD : HRD & AdministrationRAMKRISHNA FORGINGS LTD. (UNIT 3 & 4)
MKS/TPM/RKFL/01-2008
TOTAL PRODUCTIVE MAINTENANCE ….
GOAL1. Increase production while,
at the same time, increasing employee morale and job satisfaction.
2. Hold emergency & unscheduled maintenance to a minimum.
Maintenance is no – longer regarded as a Non – Profit activity.
MKS/TPM/RKFL/01-2008
TOTAL PRODUCTIVE MAINTENANCE ….
Why we need TPM ?The major objectives of the TPM are listed as under :
1. Avoid wastage in quickly changing environment.2. Reduce Cost of Manufacturing.3. Produce a low batch quantity at the earliest possible time.4. Goods send to Customers must be “ non – defective”
MKS/TPM/RKFL/01-2008
TOTAL PRODUCTIVE MAINTENANCE ….
TYPES OF MAINTENANCE1. Breakdown Maintenance2. Preventive Maintenance
a). Periodic Maintenanceb). Predictive Maintenance
3. Corrective Maintenance4. Maintenance Prevention
MKS/TPM/RKFL/01-2008
TOTAL PRODUCTIVE MAINTENANCE ….
TPM TARGETS1. PRODUCTION
I). Obtain Minimum 80% Overall Production Efficiencyii). Obtain Minimum 90% Overall Equipment
Effectivenessiii). Run the Machine during lunchtime
2. QUALITY Operate in a manner, so that there are no customer
complaint3. COST Reduce the manufacturing cost by ----- Per Cent4. DELIVERY Achieve 100% success in delivering the goods as required
by the customer5. SAFETY Maintain an accident free environment6. MULTYTASK Develop multiskilled & flexible workers.
MKS/TPM/RKFL/01-2008
TOTAL PRODUCTIVE MAINTENANCE ….
Motives of TPMa) Adoption of Life – Cycle approach for improving the overall
performance of production equipmentsb) Improving Productivity by highly motivated workers which
is achieved by Job – Enlargementc) Formation of team of volunteers for activities viz, cause of
failure, possible reduction of cycle time; and equipment / process modifications.
Uniqueness of TPM The major difference between TPM and other concepts is that the
operators are also made to involve in the maintenance process.
MKS/TPM/RKFL/01-2008
TOTAL PRODUCTIVE MAINTENANCE ….
Direct Benefits of TPM1. Increase Productivity and
Overall Plant Efficiency by 1.5 to 2 times
2. Rectify customers complaints3. Reduce manufacturing cost by
….percent4. Satisfy the customers needs
by 100%5. Reduce accidents6. Comply with all relevant
governmental regulations
Indirect Benefits of TPM1. Higher confidence level among
the workers2. Keep the work place clean, neat
and attractive3. Favourable change in the
attitude of the operators4. Achieve goals by working as
Team5. Share knowledge and
experience6. The worker get a feeling of
OWNING the machine
MKS/TPM/RKFL/01-2008
TOTAL PRODUCTIVE MAINTENANCE ….
Introducing TPM at a Production Unit
STEP – 1. Preparatory Stage Announcement by TOP MANAGEMENT to all about TPM
introduction in the organization Initial education and publicity for TPM Setting up TPM & Departmental committees Establishing the TPM working systems & target A master plan for institutionalizing
STEP – 2. Introduction StageSTEP – 3. Implementation
STEP – 4. Institutionalizing Stage
MKS/TPM/RKFL/01-2008
TOTAL PRODUCTIVE MAINTENANCE ….
TOPMANAGEMENT
TPMOFFICE TPM Responsible
Plant Manager
5 S
AutonomusMaintenance
Planned Maintenance
Individual Improvement
QualityMaintenance
Early EquipmentManagement
SafetyTraining &
Development
MKS/TPM/RKFL/01-2008
TOTAL PRODUCTIVE MAINTENANCE ….
PILLARS OF TPM
JISHU HOZENKOBETSU KAIZEN
Planned MaintenanceQuality Maintenance
TrainingOffice TPM
Safety , Health & Environment5 S
SEIRI SEITON SEISO SEIKETSU SHITSUKE
MKS/TPM/RKFL/01-2008
TOTAL PRODUCTIVE MAINTENANCE ….PILLARS OF TPM
PILLAR 1 : 5 S TPM starts with 5S. Problems can not be clearly seen
when the workplace is unorganized. Cleaning and organizing the workplace helps the team to uncover problems. Making problems visible is the FIRST STEP of improvement.SEIRI – SORTOUTSEITON – ORGANIZESEISO – SHINE THE WORKPLACESEIKETSU – STANDARDIZATIONSHITSUKE – SELF DISCIPLINE
MKS/TPM/RKFL/01-2008
TOTAL PRODUCTIVE MAINTENANCE ….PILLARS OF TPM
PILLAR 2 :JISHU HOZEN (Autonomus Maintenance) This pillar is geared towards developing
Operators to be able to take care of small maintenance tasks, thus freeing up skilled maintenance people to spend time on more value added activity and technical repairs. The operators are responsible for up keep of their equipment to prevent it from deteriorating.
MKS/TPM/RKFL/01-2008
TOTAL PRODUCTIVE MAINTENANCE ….PILLARS OF TPM
PILLAR 2 :JISHU HOZEN….
POLICY1. Uninterrupted operation of equipments2. Flexible operators to operate & maintain other equipments3. Eliminating the defects at source through active employee participation4. Stepwise implementation of JISHU HOZEN activities.JH TARGETS1. Reduce process time by ………%2. Reduce oil/ lubricants consumption by ………..%3. Increase use of JHJH STEPS1. Preparation of employees2. Initial cleanup of machines3. Take counter measures4. Fix tentative JH standards5. General inspection6. Autonomus inspection7. Standardization8. Autonomus management
MKS/TPM/RKFL/01-2008
TOTAL PRODUCTIVE MAINTENANCE ….PILLARS OF TPM
PILLAR 3 : KAIZENKAI means change and ZEN means good (for the better). Basically Kaizen is for small improvements, but carried out on a continual basis and involves all people in the organization. The principal behind is that “ a very large number of small improvements are more effective in an organizational environment than a few improvements of large value.
This pillar is aimed at reducing losses in the work place that affect our efficiencies. By using a detailed and through procedure, we eliminate losses in a systematic method using various Kaizen Tools. These activities are not restricted to production areas and can be implemented in administration area as well.
MKS/TPM/RKFL/01-2008
TOTAL PRODUCTIVE MAINTENANCE ….PILLARS OF TPM
PILLAR 3 : KAIZEN….POLICY – 1. Practice concepts of Zero Losses in every sphere of activities.2. Relentless pursuit to achieve cost reduction targets in all sources.3. Relentless pursuit to improve overall plant equipment
effectiveness.4. Extensive use of PM analysis as tool to eliminate losses.5. Focus on easy handling of operators.TARGET – Achieve and sustain zero losses with respect to minor stops,
measurement and adjustments, defects and unavoidable downtime. It also aims to achieve …..% manufacturing cost reduction.
MKS/TPM/RKFL/01-2008
TOTAL PRODUCTIVE MAINTENANCE ….PILLARS OF TPM
PILLAR 4 : PLANNED MAINTENANCE
It is aimed to have trouble free machines and equipments producing defect free products for total customer satisfaction.
With planned maintenance, we evolve an effort from a reactive to a proactive method and use trained maintenance staff to help train the operators to better maintain their equipment.
Policy:
Achieve and sustains availability of machines Optimum maintenance cost. Reduce spares inventory. Improve reliability and maintainability of machines.
MKS/TPM/RKFL/01-2008
TOTAL PRODUCTIVE MAINTENANCE ….PILLARS OF TPM
PILLAR 4 : PLANNED MAINTENANCE….
TARGET:1. Zero equipment failure and breakdown.2. Improve reliability and maintainability by 50%.3. Reduce maintenance cost by 20%.4. Ensure availability of spares all the time.
STEPS: Equipment evaluation and recording present status. Restore deterioration and improve weakness. Building up information management system. Prepare time based information system, select equipment, parts and
members and map on the plan. Prepare predictive maintenance system by introducing equipment
diagnostic techniques and Evaluation of planned maintenance.
MKS/TPM/RKFL/01-2008
TOTAL PRODUCTIVE MAINTENANCE ….PILLARS OF TPM
PILLAR 5 : QUALITY MAINTENANCE (QM) It is aimed towards customer delight through highest quality through
defect free manufacturing. Focus is on eliminating non-conformances in a systematic manner. We gain understanding of what parts of the equipment affect product quality and begin to eliminate current quality concerns then move to potential quality concerns. Transition is from reactive to proactive.
POLICY: Defect free conditions and control of equipments QM activities to support quality assurances. Focus of prevention of defects at source Focus on fool proof (POKAYOKE) system. In-line detection and segregation of defects. Effective implementation of operator quality assurance.
MKS/TPM/RKFL/01-2008
TOTAL PRODUCTIVE MAINTENANCE ….PILLARS OF TPM
PILLAR 5 : QUALITY MAINTENANCE (QM)…TARGET: Achieve and sustain customer complaints at zero. Reduce in-process defects by 50%. Reduce cost of quality by 50%.
DATA REQUIREMENTS:
Quality defects are classified as “CUSTOMER END DEFECTS” and IN HOUSE defects. For customer-end data, we have to get data on
1. Customer end line rejection 2. Field complaints In-house data include data related to products and data related to
process.
MKS/TPM/RKFL/01-2008
TOTAL PRODUCTIVE MAINTENANCE ….PILLARS OF TPM
PILLAR 6 : TRAINING It is aimed to have multi-skilled revitalized employees whose
moral is high and who has eager to come to work and perform all required functions effectively and independently. Education is given to operators to upgrade their skill.
The employees should be trained to achieve the form phase of skill which are as under:
PHASE 1: Do not know.PHASE 2: Know the theory but cannot do.PHASE 3: Can do but cannot teach.PHASE 4: Can do and also teach.
MKS/TPM/RKFL/01-2008
TOTAL PRODUCTIVE MAINTENANCE ….PILLARS OF TPM
PILLAR 6 : TRAINING….
POLICY : 1. Focus on improvement of knowledge skill & techniques.2. Creating a training environment for self learning based on felt needs.3. Training curriculum/tools/assessment etc. Conductive to employees’
revitalization.4. Training to remove employee fatigue and make work enjoyable.
TARGET:1. Achieve and sustain downtime due to want men at zero on critical
machines.2. Achieve and sustain zero losses due to lack of
knowledge/skills/Techniques3. Aim for 100% participation in suggestion scheme.
MKS/TPM/RKFL/01-2008
TOTAL PRODUCTIVE MAINTENANCE ….PILLARS OF TPM
PILLAR 6 : TRAINING….
STEPS IN TRAINING ACTIVITES:1. Setting policies and priorities and checking present status of
education and training.2. Establish of training system for operations and maintenance
skill up gradation.3. Training the employees for up gradation the operation and
maintenance skills.4. Preparation of training calendar.5. Kick-off the training.
6. Evaluation of activities and study of future approach
MKS/TPM/RKFL/01-2008
TOTAL PRODUCTIVE MAINTENANCE ….PILLARS OF TPM
PILLAR 7 : OFFICE TPM
Office TPM should be started after activating from other pillars of TPM (JH, KK, and QM.PM). Office TPM must be flowed to improve productivity, efficiency in the administrative function and identify eliminate losses. This includes analyzing process and procedure towards increased office automation. Office TPM covers twelve major losses. These are:
1. Processing loss2. Cost loss including in areas such as procurement, accounts marketing leading to high
inventories.3. Communication loss.4. Idle loss.5. Set-up loss.6. Accuracy loss7. Office equipment breakdown.8. Communication channel breakdown.9. Time spent on retrieval of information.10. Non availability of correct on line stock status.11. Customer complaints due to logistics.12. Expense on emergency dispatches/purchases.