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© of CBEPL 1 Concept Business Excellence Pvt. Ltd. TOTAL PRODUCTIVE MAINTENANCE OVERVIEW Your partner in creating High Performing World Class Organization
© of CBEPL 1
Concept Business Excellence Pvt. Ltd. TOTAL PRODUCTIVE MAINTENANCE
OVERVIEW
Your partner in creating High Performing World Class Organization
© of CBEPL 2
TPM Overview
What is TPM and Why TPM ?
TPM is a culture that focuses on improving the effectiveness of the plant,
equipment and processes through the empowerment of PEOPLE.
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Japan Institute of Plant Maintenance
• Aims at building up a corporate culture that thoroughly pursues production
system effectiveness improvement. (Overall Equipment Effectiveness :OEE)
• Constructs a system to prevent every kind of loss, for example, to achieve
"zero accidents, zero defects and zero failures", based on Gemba (actual
site) and Genbutsu (actual thing) over the entire life cycle of a production
system.
• Covers all departments including production, development, marketing and
administration.
• Requires all and full involvement from top management to frontline
employees.
• Achieves zero losses by overlapping small-group activities.
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TPM helps to achieve Zero “BAD”
• Zero Breakdown
• Zero Accident
• Zero Defects
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INTRODUCTION TO TPM
Emergence of TPM
• TPM, is a Japanese Management System. During 1950’s and 1960’s
Preventive Maintenance was very popular in Japan. Seichi Nakajima of
JIPM, first developed and named this new approach as TPM in 1971.
• TPM is later improvised by JIPM as the surest means of achieving world
class manufacturing.
• TPM® is a registered trade mark
of JIPM.
JIPM – Japanese Institute of Plant
Maintenance
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INTRODUCTION TO TPM
Development of Maintenance Systems
1950 1960 1970 1980 1990 2000
Breakdown Maintenance - Repairs
Preventive Maintenance – Periodic Maintenance
Corrective Maintenance
Predictive Maintenance – CBM
TPM – Total Productive Maintenance
1950
1957
1961
1971
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INTRODUCTION TO TPM
TPM - The major approach to create a plant in 21st century
TPM
Improved
product
quality
Enhanced
safety
record
Increased
Profile
Higher
customer
satisfaction
Reductio
n in M/c
failure
Improved
employee
morale
Cost
reduction
Increased
productivity • Initially in 1970’s JIPM introduced TPM for the
fabrication & assembly industries.
• This was developed with 5 pillars of TPM
activities.
• Today 8 pillars have been devised.
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8 Pillars of TPM
5S & Total Employee Involvement
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Definition of TPM (M: Maintenance)
• To set a goal to maximize equipment effectiveness. (overall
effectiveness).
• By establishing a total system for PM for the entire life of the
equipment.
• Participation by all departments, including equipment planning,
operating and maintenance departments.
• Involving all personnel, including top personnel to first-line operators.
• For promoting PM by motivation management, namely by autonomous small group activities
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Definition of TPM (M: Maintenance)
TPM MEANS
• Taking as a prime objective a company structure that pursues production
effectiveness to its ultimate limits. (=comprehensive effectiveness)
• Putting together a practical shop-floor system to prevent losses before
they occur throughout the entire production system's life cycle : zero
accidents, zero defects, zero breakdowns
• Involving all function, including production, development, sales and
management.
• Having all employees participate, from top executives to front-line
workers.
• Achieving zero losses through overlapping small groups.
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From TPM of Production Department to
Company-wide
TPM Covering All Company Activities
Top Management
Planning Financial Personnel General
Affairs
Plant Plant Plant Plant
Production
TPM Phase 1
Development of
Products &
Equipment Sales
TPM Phase 1 : TPM of production Department.
TPM Phase 2 : Company-wide TPM encompassing production development, sales and administration.
TPM Phase 2
Total Preventive
Maintenance
Total Productive
Management
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Results from 250 TPM Award Winners
• Increase in Productivity % 50
• Decrease in Breakdowns % 99
• Decrease in Defect Rate % 90
• Decrease in Customer Complaints % 75
• Decrease in Maintenance Cost % 30
• Decrease in WIP % 50
• Decrease in Energy Consumption % 30
• Accidents Zero
• Pollution Zero
• Increase in Employee Suggestions 10 Fold
PM Prize for TPM JIPM
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Intangible Benefits of TPM
• After introduction of autonomous maintenance activity, operators take
care of machines by themselves without being ordered to.
• With achievement of Zero Breakdown and Zero Defects, operators get
new confidence in their own abilities
• Work Places which used to be covered with oil and chips are now so
clean and pleasant as to be almost un-recognisable.
• Improved image of the company leading to the possibility of increased
orders.
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TPM – Way of Life
• Breakdown needs to be measured not in 3 digits but in single digit -
ultimately to zero.
• Accidents needs to be measured by “no. of dangerous working
conditions” “not by no. of accidents occurred (near miss count).
• Defects needs to be measured by ppm not as a percentage.
• Hence TPM must be driven by top person and must come as a way of
life in your company.
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12 Steps of TPM Development Programs
1. Declaration by top management to introduce TPM – Declared in TPM in
house seminar, Company magazine.
2. Introductory education & campaign for TPM
3. Establishing TPM promotion organization – Committees & Sub-
Committees.
4. Setting basic principles and target for TPM
5. Creation of Master plan for establishing TPM
6. Kick-Off of TPM
(Preparations for Introduction)
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12 Steps of TPM Development Programs
7. Establishing systems for improving production efficiency.
7.1 – Individual Improvement
7.2 – Autonomous maintenance
7.3 – Planned maintenance
7.4 – Operation & maintenance skills upgrading training
8. Establishing initial control systems for new products and equipment.
9. Establishing Quality maintenance organization.
10. Establishing systems to improve efficiency of administration and other indirect departments
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12 Steps of TPM Development Programs
11. Establishing Systems to control safety, Health and environments.
12. Total Application of TPM and raising its level
-Application of PM award
-Challenge for higher target.
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This is a never ending journey…
Thank You For Your Kind Attention
