Hrm Presentation on Tpm

8/2/2019 Hrm Presentation on Tpm

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MKS/TPM/RKFL/01-2008

TOTAL PRODUCTIVE

MAINTENANCE


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Group no.5

Reshu

Ruchika

Samantha

Sandeep Monga

Sandeep Kumar

Sachin

Shifali

Shimon

ShilpiMKS/TPM/RKFL/01-2008


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TOTAL PRODUCTIVE MAINTENANCE .

GOAL

1. Increase production while,at the same time, increasing

employee morale and jobsatisfaction.

2. Hold emergency &unscheduled maintenance to

a minimum.


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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


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TYPES OF MAINTENANCE

1. Breakdown Maintenance

2. Preventive Maintenance

a). Periodic Maintenance

b). Predictive Maintenance

3. Corrective Maintenance

4. Maintenance Prevention


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TPM TARGETS

1. 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 nocustomer complaint

3. COST

Reduce the manufacturing cost by ----- Per Cent4. DELIVERY

Achieve 100% success in delivering the goods asrequired by the customer

5. SAFETY

Maintain an accident free environment6. MULTYTASK

Develop multiskilled & flexible workers.


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Motives of TPM

a) Adoption of Life Cycle approach for improving the overallperformance of production equipments

b) 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 TPMThe major difference between TPM and other concepts is that theoperators are also made to involve in the maintenance process.


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Direct Benefits of TPM1. Increase Productivity and

Overall Plant Efficiency by1.5 to 2 times

2. Rectify customerscomplaints

3. Reduce manufacturing costby .percent

4. Satisfy the customersneeds by 100%

5. Reduce accidents

6. Comply with all relevantgovernmental regulations

Indirect Benefits ofTPM

1. Higher confidence levelamong the workers

2. Keep the work place clean,neat and attractive

3. Favorable change in theattitude of the operators

4. Achieve goals by working as

Team5. Share knowledge and

experience

6. The worker get a feeling ofOWNING the machine


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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 Stage

STEP 3. Implementation

STEP 4. Institutionalizing Stage


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TOPMANAGEMENT

TPMOFFICE

TPM ResponsiblePlant Manager

5 S

AutonomousMaintenance

PlannedMaintenance

Individual

Improvement

QualityMaintenance

Early EquipmentManagement

Safety Training &Development


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TOTAL PRODUCTIVE MAINTENANCE .Pillars of TPM

JISHU

HOZEN

OFFICE

TPM

PLANNED

MAINTE-

NANCE

QUALITY

MAINTE-

NANCE

TRAINING

SEIRI SEITON SEISO SEIKETSU SHITSUKE


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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 uncoverproblems. Making problems visible is the FIRSTSTEP of improvement.SEIRI SORTOUT

SEITON ORGANIZE

SEISO

SHINE THE WORKPLACE

SEIKETSU STANDARDIZATION

SHITSUKE SELF DISCIPLINE


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PILLAR 2 :JISHU HOZEN

(Autonomous Maintenance)

This pillar is geared towards developingOperators to be able to take care of

small maintenance tasks, thus freeingup skilled maintenance people tospend time on more value addedactivity and technical repairs. Theoperators are responsible for up keep

of their equipment to prevent it fromdeteriorating.


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PILLAR 2 :JISHU HOZEN.

JH POLICY

1. Uninterrupted operation of equipments2. Flexible operators to operate & maintain other

equipments

3. Eliminating the defects at source through active

employee participation

4. Stepwise implementation of JISHU HOZENactivities.


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JH TARGETS

Reduce process time by %

Reduce oil/ lubricants consumptionby ..%

Increase use of JH


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JH STEPS

Preparation of employees

Initial cleanup of machines

Take counter measures Fix tentative JH standards

General inspection

Autonomus inspection

Standardization

Autonomus management


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PILLAR 3 : PLANNED MAINTENANCE

It is aimed to have trouble free machines and equipments producingdefect free products for total customer satisfaction.

With planned maintenance, we evolve an effort from a reactive to aproactive method and use trained maintenance staff to help train theoperators to better maintain their equipment.

Policy:

Achieve and sustains availability of machines Optimum maintenance cost. Reduce spares inventory. Improve reliability and maintainability of machines.


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PILLAR 3 : 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.


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PILLAR 4 : QUALITY MAINTENANCE (QM)

It is aimed towards customer delight through highest quality throughdefect free manufacturing. Focus is on eliminating non-conformancesin a systematic manner. We gain understanding of what parts of theequipment affect product quality and begin to eliminate current quality

concerns then move to potential quality concerns. Transition is fromreactive to proactive.

POLICY:

Defect free conditions and control of equipments QM activities to support quality assurances.

Focus of prevention of defects at source In-line detection and segregation of defects. Effective implementation of operator quality assurance.


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PILLAR 4: 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 andIN HOUSE defects. For customer-end data, we have to get data on

1. Customer end line rejection2. Field complaints

In-house data include data related to products and data related toprocess.


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PILLAR 5 : TRAINING

It is aimed to have multi-skilled revitalized employees whosemoral is high and who are eager to come to work and performwith all required functions effectively and independently.

Education is given to operators to upgrade their skill.


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PILLAR 5 : TRAINING.

POLICY :1. Focus on improvement of knowledge skill & techniques.2. Creating a training environment .

3. Training curriculum/tools/assessment etc. Conductive to employeesrevitalization.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.


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PILLAR 5 : 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 andmaintenance skills.

4. Preparation of training calendar.

5. Kick-off the training.

6. Evaluation of activities and study of future approach


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OFFICE TPM

Office TPM must be followed to improve productivity, efficiency in theadministrative function and identify eliminate losses.. This includesanalyzing process and procedure towards increased office automation.Office TPM covers eight major losses. These are:

1. Processing loss2. Communication loss.3. Idle loss.4. Set-up loss.5. Accuracy loss6. Office equipment breakdown.7. Communication channel breakdown.8. Time spent on retrieval of information.


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THANK YOU.


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Hrm Presentation on Tpm

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