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What is Total Productive

Maintenance ( TPM ) ?Total Productive Maintenance (TPM) is a

maintenance program which involves a newly

defined concept for maintaining plants andequipment. The goal of the TPM program is tomarkedly increase production while, at the sametime, increasing employee morale and job

satisfaction. TPM brings maintenance into focus asa necessary and vitally important part of thebusiness. It is no longer regarded as a non-profitactivity.

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Why TPM ?

TPM was introduced to achieve the followingobjectives. The important ones are listedbelow.

i. Avoid wastage in a quickly changing economicenvironment.

ii. Producing goods without reducing productquality.

iii. Reduce cost.

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

v. Goods send to the customers must be nondefective.

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Types of maintenance :1. Breakdown maintenance :

It means that people waits until equipment fails and repair it.Such a thing could be used when the equipment failuredoes not significantly affect the operation or production orgenerate any significant loss other than repair cost.

2. Preventive maintenance ( 1951 ):

It is a daily maintenance ( cleaning, inspection, oiling and re-tightening ), design to retain the healthy condition ofequipment and prevent failure through the prevention ofdeterioration, periodic inspection or equipment conditiondiagnosis, to measure deterioration. It is further divided intoperiodic maintenance and predictive maintenance. Just likehuman life is extended by preventive medicine, theequipment service life can be prolonged by doing preventivemaintenance

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Cont

2a. Periodic maintenance ( Time based maintenance -TBM) :

Time based maintenance consists of periodicallyinspecting, servicing and cleaning equipment andreplacing parts to prevent sudden failure and process

problems.2b. Predictive maintenance : This is a method in which the service life of important

part is predicted based on inspection or diagnosis, inorder to use the parts to the limit of their service life.

Compared to periodic maintenance, predictivemaintenance is condition based maintenance. Itmanages trend values, by measuring and analyzing dataabout deterioration and employs a surveillance system,designed to monitor conditions through an on-linesystem.

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Cont

3. Corrective maintenance ( 1957 ) :

It improves equipment and its components so thatpreventive maintenance can be carried out reliably.Equipment with design weakness must be redesigned to

improve reliability or improving maintainability4. Maintenance prevention ( 1960 ):

It indicates the design of a new equipment. Weakness ofcurrent machines are sufficiently studied ( on site

information leading to failure prevention, easiermaintenance and prevents of defects, safety and ease ofmanufacturing ) and are incorporated beforecommissioning a new equipment.

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Pillars of TPM

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PILLAR 1 - 5S :

TPM starts with 5S. Problems cannot beclearly seen when the work place is

unorganized. Cleaning and organizing theworkplace helps the team to uncoverproblems. Making problems visible is thefirst step of improvement

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PILLAR 2 - JISHU HOZEN ( Autonomous maintenance ) :

This pillar is geared towards developingoperators to be able to take care of smallmaintenance tasks, thus freeing up the skilledmaintenance people to spend time on more

value added activity and technical repairs. Theoperators are responsible for upkeep of theirequipment to prevent it from deteriorating.

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PILLAR 3 - KAIZEN : Kai" means change, and "Zen" means good ( for the

better ). Basically kaizen is for small improvements,but carried out on a continual basis and involve allpeople in the organization. Kaizen is opposite to bigspectacular innovations. Kaizen requires no or littleinvestment. The principle behind is that "a very

large number of small improvements are moveeffective in an organizational environment than afew improvements of large value. This pillar isaimed at reducing losses in the workplace thataffect our efficiencies. By using a detailed andthorough procedure we eliminate losses in asystematic method using various Kaizen tools.These activities are not limited to production areasand can be implemented in administrative areas as

well.

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PILLAR 4 - PLANNED MAINTENANCE :

It is aimed to have trouble free machines andequipments producing defect free products fortotal customer satisfaction. This breaksmaintenance down into 4 "families" or groupswhich was defined earlier.

1. Preventive Maintenance

2. Breakdown Maintenance

3. Corrective Maintenance

4. Maintenance Prevention

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PILLAR 5 - QUALITY MAINTENANCE :

It is aimed towards customer delight through highest quality throughdefect free manufacturing. Focus is on eliminating non-conformances in a systematic manner, much like FocusedImprovement. We gain understanding of what parts of theequipment affect product quality and begin to eliminate currentquality concerns, then move to potential quality concerns. Transition

is from reactive to proactive (Quality Control to Quality Assurance).

QM activities is to set equipment conditions that preclude qualitydefects, based on the basic concept of maintaining perfectequipment to maintain perfect quality of products. The condition arechecked and measure in time series to very that measure values are

within standard values to prevent defects. The transition ofmeasured values is watched to predict possibilities of defectsoccurring and to take counter measures before hand.

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Policy :

1. Defect free conditions and control ofequipments.

2. QM activities to support quality assurance.

3. Focus of prevention of defects at source4. Focus on poka-yoke. ( fool proof system )

5. In-line detection and segregation of defects.

6. Effective implementation of operator qualityassurance.

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PILLAR 6 - TRAINING :

It is aimed to have multi-skilled revitalized employees whose morale ishigh and who has eager to come to work and perform all requiredfunctions effectively and independently. Education is given to operatorsto upgrade their skill. It is not sufficient know only "Know-How" by theyshould also learn "Know-why". By experience they gain, "Know-How" toovercome a problem what to be done. This they do without knowing the

root cause of the problem and why they are doing so. Hence it becomenecessary to train them on knowing "Know-why". The employees shouldbe trained to achieve the four phases of skill. The goal is to create afactory full of experts. The different phase of skills are

Phase 1 : Do not know.

Phase 2 : Know the theory but cannot do.Phase 3 : Can do but cannot teachPhase 4 : Can do and also teach.

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PILLAR 7 - OFFICE TPM :

Office TPM should be started after activating four other pillars of TPM (JH,

KK, QM, PM). Office TPM must be followed to improve productivity,efficiency in the administrative functions and identify and eliminate losses.This includes analyzing processes and procedures towards increased officeautomation. Office TPM addresses twelve major losses. They are

Processing loss Cost loss including in areas such as procurement, accounts, marketing,

sales leading to high inventories

Communication loss Idle loss Set-up loss Accuracy loss Office equipment breakdown Communication channel breakdown, telephone and fax lines Time spent on retrieval of information Non availability of correct on line stock status Customer complaints due to logistics Expenses on emergency dispatches/purchases

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PILLAR 8 - SAFETY, HEALTH AND ENVIRONMENT :Target :

Zero accident, Zero health damage Zero fires.

In this area focus is on to create a safe workplace and a surrounding

area that is not damaged by our process or procedures. This pillar willplay an active role in each of the other pillars on a regular basis.

A committee is constituted for this pillar which comprises representativeof officers as well as workers. The committee is headed by Senior vicePresident ( Technical ). Utmost importance to Safety is given in the

plant. Manager (Safety) is looking after functions related to safety. Tocreate awareness among employees various competitions like safetyslogans, Quiz, Drama, Posters, etc. related to safety can be organized atregular intervals.

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Conclusion:

Today, with competition in industry at an all time high,TPM may be the only thing that stands between successand total failure for some companies. It has been provento be a program that works. It can be adapted to work

not only in industrial plants, but in construction, buildingmaintenance, transportation, and in a variety of othersituations. Employees must be educated and convincedthat TPM is not just another "program of the month" andthat management is totally committed to the program

and the extended time frame necessary for fullimplementation. If everyone involved in a TPM programdoes his or her part, an unusually high rate of returncompared to resources invested may be expected.

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