+ All Categories
Home > Documents > Prof.A.Das, MIMTS &. CONCEPT “Unless the machine and equipment are in good condition with high...

Prof.A.Das, MIMTS &. CONCEPT “Unless the machine and equipment are in good condition with high...

Date post: 16-Jan-2016
Category:
Upload: roland-nichols
View: 216 times
Download: 0 times
Share this document with a friend
Popular Tags:
28
Prof.A.Das, MIMTS &
Transcript
Page 1: Prof.A.Das, MIMTS &. CONCEPT “Unless the machine and equipment are in good condition with high process capabilities, one cannot expect defect free production.”

Prof.A.Das, MIMTS

&

Page 2: Prof.A.Das, MIMTS &. CONCEPT “Unless the machine and equipment are in good condition with high process capabilities, one cannot expect defect free production.”

CONCEPT

“Unless the machine and equipment are in good condition with high process capabilities, one cannot expect defect free production.”

Page 3: Prof.A.Das, MIMTS &. CONCEPT “Unless the machine and equipment are in good condition with high process capabilities, one cannot expect defect free production.”

TQM

Page 4: Prof.A.Das, MIMTS &. CONCEPT “Unless the machine and equipment are in good condition with high process capabilities, one cannot expect defect free production.”

TQM: A “Buzzword” Losing Popularity

• For many companies, the term TQM is associated with corporate programs (mid 1980s ~ early 1990s) aimed at implementing employee teams and statistical process control.

• Unfortunately, many companies were dissatisfied with the perceived results of these programs, concluding TQM does not work.

Question: Why were they dissatisfied? Were they justified?

Page 5: Prof.A.Das, MIMTS &. CONCEPT “Unless the machine and equipment are in good condition with high process capabilities, one cannot expect defect free production.”

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 managing Therefore, TQM is the art of managing the whole to achieve excellencethe whole to achieve excellence.

Page 6: Prof.A.Das, MIMTS &. CONCEPT “Unless the machine and equipment are in good condition with high process capabilities, one cannot expect defect free production.”

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

Page 7: Prof.A.Das, MIMTS &. CONCEPT “Unless the machine and equipment are in good condition with high process capabilities, one cannot expect defect free production.”

What’s the goal of TQM?

• “Do the right things right the first time, every time.”• Another way to put it

I. total client satisfaction through quality products and services

II. continuous improvements to processes, systems, people, processes, systems, people, suppliers, partners, products, and servicessuppliers, partners, products, and services

Page 8: Prof.A.Das, MIMTS &. CONCEPT “Unless the machine and equipment are in good condition with high process capabilities, one cannot expect defect free production.”

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.

Page 9: Prof.A.Das, MIMTS &. CONCEPT “Unless the machine and equipment are in good condition with high process capabilities, one cannot expect defect free production.”

The TQM System

Total Quality Management

CustomerFocus

ProcessImprovement

TotalInvolvement

LeadershipEducation and Training Supportive structureCommunications Reward and recognitionMeasurement

ContinuousImprovement

Objective

Principles

Elements

Page 10: Prof.A.Das, MIMTS &. CONCEPT “Unless the machine and equipment are in good condition with high process capabilities, one cannot expect defect free production.”

TPM

Page 11: Prof.A.Das, MIMTS &. CONCEPT “Unless the machine and equipment are in good condition with high process capabilities, one cannot expect defect free production.”

Origins of TPM

• Dr. Edward W 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

Page 12: Prof.A.Das, MIMTS &. CONCEPT “Unless the machine and equipment are in good condition with high process capabilities, one cannot expect defect free production.”

Journey of Maintenance Management

(Breakdown maintenance=BM)

(Profitable preventive maintenance PPM=BM+PM)

(Productive maintenance=BM+PM+MI+PM)

(Total productive maintenance, TPM=BM+PM+MI+PM+CI)

Page 13: Prof.A.Das, MIMTS &. CONCEPT “Unless the machine and equipment are in good condition with high process capabilities, one cannot expect defect free production.”

Four Maintenance Models

• Corrective Maintenance

• Preventive Maintenance

• Predictive Maintenance

• Total Productive Maintenance

Page 14: Prof.A.Das, MIMTS &. CONCEPT “Unless the machine and equipment are in good condition with high process capabilities, one cannot expect defect free production.”

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.

Page 15: Prof.A.Das, MIMTS &. CONCEPT “Unless the machine and equipment are in good condition with high process capabilities, one cannot expect defect free production.”

15

PRINCIPLES PRINCIPLES

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 failure

3. Predictive and condition-based maintenance: Reducing fixed-time maintenance and relying on the condition of equipment to determine maintenance activity

Page 16: Prof.A.Das, MIMTS &. CONCEPT “Unless the machine and equipment are in good condition with high process capabilities, one cannot expect defect free production.”

Eight major pillars of TPM

Aut

onom

ous

Mai

nten

ance

Pla

nned

Mai

nten

ance

Equ

ipm

ent

and

proc

ess

impr

ovem

ent

Ear

ly m

anag

emen

t of

new

equ

ipm

ent

Pro

cess

qua

lity

man

agem

ent

TP

M in

the

off

ice

Education and trainingSafety and environmental management

Page 17: Prof.A.Das, MIMTS &. CONCEPT “Unless the machine and equipment are in good condition with high process capabilities, one cannot expect defect free production.”

• 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

Page 18: Prof.A.Das, MIMTS &. CONCEPT “Unless the machine and equipment are in good condition with high process capabilities, one cannot expect defect free production.”

IMPLEMENTATION

Page 19: Prof.A.Das, MIMTS &. CONCEPT “Unless the machine and equipment are in good condition with high process capabilities, one cannot expect defect free production.”

TQM Implementation1. Capitalize on the current village / fatherland-like

culture to facilitate the TQM process. Ensure that the change stays and has the desired results.

2. Training in the basic elements of TQM must be provided to all employees

3. Involved all employees in the process. Ensures that they actually take "ownership" of the process to facilitate the success of the program.

Page 20: Prof.A.Das, MIMTS &. CONCEPT “Unless the machine and equipment are in good condition with high process capabilities, one cannot expect defect free production.”

CONTD…

4.Choosing a quality management system that defines and covers all spheres of the operation

Identifying and meeting the needs and requirements of customers, design, planning, purchasing, manufacturing, marketing, packaging, storage, delivery, etc.

Also include all relevant activities such as finance, personnel, and administration.  

 

Page 21: Prof.A.Das, MIMTS &. CONCEPT “Unless the machine and equipment are in good condition with high process capabilities, one cannot expect defect free production.”

TPM Implementation12 steps

Preparation

Kick-off

Implementation

Announcement to introduce TPM

Introductory 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 program

Increase skills of production and maintenance personnel

Perfect TPM implementation and raise TPM levelsStabilization

Develop early equipment management program

Invite customers, affiliated companies and subcontractors

Page 22: Prof.A.Das, MIMTS &. CONCEPT “Unless the machine and equipment are in good condition with high process capabilities, one cannot expect defect free production.”

7 Visual Quality Management Tools forTPM Problem Solving

Page 23: Prof.A.Das, MIMTS &. CONCEPT “Unless the machine and equipment are in good condition with high process capabilities, one cannot expect defect free production.”

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

Page 24: Prof.A.Das, MIMTS &. CONCEPT “Unless the machine and equipment are in good condition with high process capabilities, one cannot expect defect free production.”

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

Page 25: Prof.A.Das, MIMTS &. CONCEPT “Unless the machine and equipment are in good condition with high process capabilities, one cannot expect defect free production.”

Career Opportunities in TQM & TPM

• TPM officer

• Process Improvement Manager

• Quality Consultant

Page 26: Prof.A.Das, MIMTS &. CONCEPT “Unless the machine and equipment are in good condition with high process capabilities, one cannot expect defect free production.”

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 atZero 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 automation• Poka-yoke(Zero Defect)

Page 27: Prof.A.Das, MIMTS &. CONCEPT “Unless the machine and equipment are in good condition with high process capabilities, one cannot expect defect free production.”

5S Housekeeping - to organize the workplace

Sort Sort the useful from the unnecessary. Things that should remain in a work area are the parts, tools, & instructions needed to do the job.

Straighten Everything has a place; everything is in its place.Display Visual Scoreboard .

Sweep

Make workplace clean. Painting, sweeping, washing, rinsing, scrubbing, and whatever else is needed to make your work place shine.

Standardize Routine cleaning becomes a way of life. Preventative maintenance by the people that know that work..

Sustain 5S becomes a routine way of life. Root causes are routinely identified and dealt with. Supervisors & workers appreciate the benefits of 5S

Safety Make workplace safe-6S program

Page 28: Prof.A.Das, MIMTS &. CONCEPT “Unless the machine and equipment are in good condition with high process capabilities, one cannot expect defect free production.”

“Quality is a Journey, not a Destination”


Recommended