Total Productive Maintenance Presentation

8/3/2019 Total Productive Maintenance Presentation

1/24

TOTAL PRODUCTIVEMAINTENANCE

Group 1,

Arunagiri. G (10MBA06),

Gokilavani. N (10MBA17),

Prabhu. K (10MBA38),

Sowbashini. B (10MBA55).

1Maintenance Management


2/24

Contents

Objectives of TPM

Targets of TPM

Overall Equipment Efficiency Stages in TPM

Steps in introduction of TPM in a organization

Pillars of TPM



3/24

Objectives

1. Avoid wastage in a quickly changing economicenvironment.

2. Producing goods without reducing productquality.

3. Reduce cost.

4. Produce a low batch quantity at the earliestpossible time.

5. Goods send to the customers must be nondefective



4/24

Targets

Obtain Minimum 80% OPE.

Obtain Minimum 90% OEE

Run the machines even during lunch. ( Lunch isfor operators and not for machines ! )

Operate in a manner, so that there are no customer

complaints. Reduce the manufacturing cost by 30%.



5/24

Maintain a accident free environment.

Increase the suggestions by 3 times.

Develop Multi-skilled and flexible workers

Achieve 100% success in delivering the goods as

required by the customer.

Targets



6/24

Overall Equipment Efficiency

OEE = A x PE x Q

A - Availability of the machine. Availability isproportion of time machine is actually available

out of time it should be available.

A = ( MTBF - MTTR ) / MTBF.



7/24

MTBF - Mean Time Between Failures = ( Total

Running Time ) / Number of Failures.

MTTR - Mean Time To Repair.

PE - Performance Efficiency. It is given by RE X

SE.

Rate efficiency (RE) : Actual average cycle time is

slower than design cycle time because of jams, etc.Output is reduced because of jams



8/24

Speed efficiency (SE) : Actual cycle

time is slower than design cycle timemachine output is reduced because it

is running at reduced speed.

Q - Refers to quality rate. Which is

percentage of good parts out of total

produced sometimes called "yield".



9/24

Stages in TPM

PREPARATORY STAGEINTRODUCTION

STAGE

IMPLEMENTATIONINSTITUTIONALISING

STAGE



10/24

Steps in introduction of TPM in

a organization Announce Top Managements Decision to Introduce

TPM

Launch Educational Campaign CreateOrganizations to Promote TPM

Establish Basic TPM Policies and Goals

Formulate a Master Plan for TPM Development

Hold TPM Kickoff

Improve Equipment Effectiveness



11/24

Establish an Autonomous Maintenance Program for

Operators

Set-up a Scheduled Maintenance Program for theMaintenance Department

Conduct Training to Improve Operation and

Maintenance Skills

Develop Initial Equipment Management Program

Implement TPM Fully and Aim for Higher Goals


Steps (contd.)


12/24

12


13/24

5S The Foundation ofTPM

Japanese Term Meaning

Seiri Sort

Seiton Organize

Seiso Clean

Seiketsu Standardize

Shitsuke Discipline



14/24

Jishu Hozen

It means Autonomous Maintenance

The operators are responsible for upkeep of their

equipment to prevent it from deteriorating.

The goals are,

Uninterrupted operation of equipment

Flexible operators who can operate and maintain

other equipment Elimination of defects at the source through active

employee participation



15/24

Jishu Hozen



16/24

Kobetsu Kaizen

Kaizen is small improvements carried out on acontinual basis and involves all people in theorganization.

Kobetsu Kaizen uses a special event approach that

focuses on improvements associated withmachines.

Examples

Relocating gauges and grease fittings for easier access.

Making shields that minimize contamination.

Centralizing lubrication points.

Making debris collection accessible.



17/24

Planned Maintenance

To have trouble-free machines and equipmentthat produce defect-free products for totalcustomer satisfaction.

Planned Maintenance achieves and sustainsavailability of machines at an optimum

maintenance cost, reduces spares inventory,and improves reliability and maintainability ofmachines.



18/24

Steps in Planned Maintenance

1. Evaluate and record present equipment status.

2. Restore deterioration and improve weaknesses.

3. Build information management system.

4. Prepare time-based data system, select

equipment, parts, and team, and make plan.

5. Prepare predictive maintenance system by

introducing equipment diagnostic techniques.

6. Evaluate planned maintenance.



19/24

Quality Maintenance

Targets customer satisfaction through defect

free manufacturing of the highest quality

products.

Through QM we gain an understanding of

what parts of the equipment affect product

quality, eliminate quality concerns, and then

move to potential quality concerns.



20/24

Training

To have multi-skilled revitalized employees

whose morale is high and who are eager to

come to work and perform all required

functions effectively and independently.

It is not sufficient for operators to learn how

to do something; they should also learn why

they are doing it and when it should be done.



21/24

Office TPM

Office TPM must be followed to improveproductivity, efficiency in the administrativefunctions, and identify and eliminate losses.

Office TPM addresses twelve major losses:

1. Processing loss

2. Cost loss including in areas such as

procurement, accounts, marketing, salesleading to high inventories

3. Communication loss

4. Idle loss



22/24

Office TPM (contd.)

5. Set-up loss

6. Accuracy loss

7. Office equipment breakdown

8. Communication channel breakdown, telephoneand fax lines

9. Time spent on retrieval of information

10. Unavailability of correct on-line stock status11. Customer complaints due to logistics

12. Expenses on emergency dispatches/purchases



23/24

Safety, Healthand Environment

The targets are,

Zero accidents,

Zero health damage, and

Zero fires.

The focus is on creating a safe workplace and

surrounding areas that are not damaged by

our process or procedures.



24/24

Thank You


Date post:	06-Apr-2018
Category:	Documents
Upload:	prithiviraj-balachandran
View:	250 times
Download:	0 times

Total Productive Maintenance Presentation

Documents