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Learning Objective
Understand the concept and philosophy of TPM
Learn the 8 pillars of TPM activities and step-by-step
implementation approach
Learn the TPM tools and be able to identify and eliminate loss
Learn how to kick-start TPM deployment with Autonomous
Maintenance, Planned Maintenance, Focused Improvement,
and Education & Training activities to improve equipment
effectiveness
Understand the roles of a TPM implementation organization
and the critical success factors
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Outline
1. Overview of TPM
2. TPM Foundation: 5S & Visual Management
3. Key Tools For TPM
4. Equipment Loss Analysis & OEE
5. The Eight Pillars of TPM
6. TPM Implementation
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What is TPM?
Total Productive Maintenance (TPM) is a method
To achieve maximum equipment effectiveness
Through employee involvement
Overview of TPM
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TPM principles
• Increase Overall Equipment Effectiveness
(OEE)
• Improve existing planned maintenance systems
• The operator is the best condition monitor
• Provide training to upgrade operations and
maintenance skills
• Involve everyone and utilize cross-functional
teamwork
Overview of TPM
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Why is TPM Important?
1. It guarantees dramatic results (Significant
tangible results)
• Reduce equipment breakdowns
• Minimize idle time and minor stops
• Less quality defects and claims
• Increase productivity
• Reduce manpower and cost
• Lower inventory
• Reduce accidents
Overview of TPM
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Cont..
2. Visibly transform the workplace (plant
environment)
• Through TPM, a filthy, rusty plant covered in oil and
grease, leaking fluids and spilt powders can be
reborn as a pleasant and safe working environment
• Customers and other visitors are impressed by the
change
• Confidence on plant’s product increases
Overview of TPM
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Cont..
3. Raises the level of workers knowledge and
skills
As TPM activities begin to yield above
concrete results, it helps:
• The workers to become motivated
• Involvement increases
• Improvement suggestions proliferate
• People begin to think of TPM as part of the job
Overview of TPM
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TPM Goal
• Maximize equipment
effectiveness
• Zero breakdowns
• Zero Defect
• Zero Accidents
Overview of TPM
Zero Waste !
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Tangible and Intangible Benefits of TPM
Tangible benefits:
Productivity up due to
Sudden breakdowns down
Overall facilities effectiveness up
Process defect rate down
Customer compliant/claims down
Products and work-in-process down
Shutdown accidents down
Pollution incidents down
Improvement suggestions up
Overview of TPM
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Tangible benefits (contd.):
Financial losses drop due to reduction in breakdowns
Repair costs drop
Maintenance labour-hours reduce
Energy costs reduce
Company’s manufacturing profit ratio up
Overview of TPM
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Intangible benefits
Achieving full-self management
• Operators have ownership of their equipments
• They look after it by themselves without direction
Eliminating breakdowns and defects
Growing confidence and ‘can-do’ attitude
Making previously dirty and oily workplaces to a
unrecognizably clean, bright and lively
Giving better image to the visitors and thereby getting
more orders
Overview of TPM
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TPM Tools
• Small group activities
• Suggestion system
• Fuguai tagging
• One point lessons
• Activity board
Key TPM Tools
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Fuguai Tagging
• Fuguai Tags are attached to
equipment where problems are
discovered
• 2 categories of Fuguai Tags:
• Blue Tag – repairs by operator
• Red Tag – repairs by
maintenance staff
• Fuguai Register
• A log for all Fuguai’s issued
and resolved
TPM Foundation
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3 Purposes of One-Point Lesson
1. To help sharpen equipment-related
knowledge and skills and communicate
information about specific problems and
improvement
2. To share important information easily when it
is needed
3. To improve the performance of the entire
team
Key TPM Tools
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Goal of Autonomous
Maintenance
Autonomous Maintenance
Prevent
Equipment
Deterioration
Equipment
Restoration
Proper
Management
Establish Basic
Condition
Goal of
Autonomous
Maintenance
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7 Steps of Autonomous Maintenance
1. Clean and inspect
2. Eliminate problem sources and inaccessible areas
3. Draw up cleaning and lubricating standards
4. Conduct general inspections
5. Conduct autonomous inspections
6. Standardize through visual workplace management
7. Implement autonomous equipment management
Autonomous Maintenance
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Example: Use of Match Marks
Autonomous Maintenance
Match marks are placed
on bolts and nuts so that
operator can easily detect
if bolts have been loosen
due to excessive
vibrations. These are
being placed on critical
bolts after each bolt had
received their correct
torque.
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Example: Colour –coded lubrication container station
Autonomous Maintenance
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What is Preventive Maintenance?
• Daily maintenance to prevent
deterioration
• Inspections to measure
deterioration
• Regular operating checkups
• Early treatment to correct the
defects of deterioration
• Planned Maintenance
Planned Maintenance
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The Four Key TPM Pillars that are Critical for Equipment Reliability
Planned Maintenance
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How to Sustain TPM
• Engaging employees
• Aim for early success
• Providing active leadership
• Share success stories
• Rewards and recognition
• Continuously improve OEE
• Evolving the TPM initiative
over time and integration with
Lean
Sustaining TPM
Effort Consulting
Get in touch with us
Efforts Consulting Pvt. Ltd.
508, Palladium Business Centre,
Opp. 4D Square Mall,
Near IIT Engg. College,
Gandhinagar Road, Ahmadabad – 382424
(+91) 9879391004
www.effortsconsulting.com
TRAINING / COACHING / CONSULTING
@ EFFORT CONSULTING 39
Our services
• Business Transformation
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