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    Total Productive Maintenance - PNKJ

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    Total Productive Maintenance (TPM) is a maintenance program that involves maintaining plants and equipment through a newly defined concept. The goal of TPM is to increase production while also boosting employee morale and satisfaction. TPM originated in Japan in the 1950s and was first implemented by Nippondenso in the 1960s. It utilizes approaches like autonomous maintenance, where operators learn to perform small maintenance tasks, and planned maintenance to have trouble-free equipment producing defect-free products. Successful TPM implementation improves overall equipment effectiveness, reduces costs and defects, and increases benefits like higher skills, job satisfaction, and confidence among employees.

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    Total Productive Maintenance - PNKJ

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    pankajluvsu
    916 views28 pages
    Total Productive Maintenance (TPM) is a maintenance program that involves maintaining plants and equipment through a newly defined concept. The goal of TPM is to increase production while also boosting employee morale and satisfaction. TPM originated in Japan in the 1950s and was first implemented by Nippondenso in the 1960s. It utilizes approaches like autonomous maintenance, where operators learn to perform small maintenance tasks, and planned maintenance to have trouble-free equipment producing defect-free products. Successful TPM implementation improves overall equipment effectiveness, reduces costs and defects, and increases benefits like higher skills, job satisfaction, and confidence among employees.

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    Total Productive Maintenance (TPM) is a maintenance program that involves maintaining plants and equipment through a newly defined concept. The goal of TPM is to increase production while also boosting employee morale and satisfaction. TPM originated in Japan in the 1950s and was first implemented by Nippondenso in the 1960s. It utilizes approaches like autonomous maintenance, where operators learn to perform small maintenance tasks, and planned maintenance to have trouble-free equipment producing defect-free products. Successful TPM implementation improves overall equipment effectiveness, reduces costs and defects, and increases benefits like higher skills, job satisfaction, and confidence among employees.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    916 views28 pages

    Total Productive Maintenance - PNKJ

    Uploaded by

    pankajluvsu
    Total Productive Maintenance (TPM) is a maintenance program that involves maintaining plants and equipment through a newly defined concept. The goal of TPM is to increase production while also boosting employee morale and satisfaction. TPM originated in Japan in the 1950s and was first implemented by Nippondenso in the 1960s. It utilizes approaches like autonomous maintenance, where operators learn to perform small maintenance tasks, and planned maintenance to have trouble-free equipment producing defect-free products. Successful TPM implementation improves overall equipment effectiveness, reduces costs and defects, and increases benefits like higher skills, job satisfaction, and confidence among employees.

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    of 28

    TOTAL PRODUCTIVE

    MAINTENANCE

    PRESENTED BY
    KARAN PARMAR
    1530/06,IEM-2
    NIT KKR.
    DEFINITION
    Total Productive Maintenance
    (TPM) is a maintenance program
    which involves a newly defined
    concept for maintaining plants
    and equipment. The goal of the
    TPM program is to markedly
    increase production while, at the
    same time, increasing employee
    morale and job satisfaction.
    HISTORY:-
     Evolved from TQM.
     Japanese concept. (1951)

     Nippondenso was the first company.(1960)

     The first widely attended TPM conference


    held in the United States occurred in 1990.
    TYPES OF
    MAINTENANCE
    1. Breakdown maintenance
    2. Preventive maintenance
    2a. Periodic maintenance ( Time based
    maintenance - TBM)
    2b. Predictive maintenance
    3. Corrective maintenance
    4. Maintenance prevention
    LIFETIME FAILURE RATES

    “normal” failure Wearout


    failure

    Failure
    rate
    improper use
    failure

    Lifetime
    SHIFT IN
    ATTITUDES

    Operator Maintenance Operator


    Maintenance

    I use I maintain &


    I fix We maintain

    Conventional NEW TPM


    AUTONOMOUS MAINTENANCE
    The principal way in which production workers
    participate in TPM

    Purpose

    2. Helps operators learn more about their


    equipment.

    4. Prepares operators to be active partners with


    maintenance and engineering in improving
    equipment performance and reliability
    BENEFITS OF TPM FOR
    OPERATORS & MAINTENANCE
    PERSONNEL

     Increased skills through additional training


     Better job satisfaction
     More challenging work
     More involvement in solving equipment problems
     Workers gets the feeling of owning of machine.
     Better job security
    INTRODUCTIO
    N OF TPM IN
    AN
    ORGANIZATIO
    N
    VARIOUS STAGES :

    a). PREPARATORY STAGE


    b). INTRODUCTION STAGE
    c). IMPLEMENTATION
    d). INSTITUTIONALISING STAGE
    Pillars of
    TPM
    PILLAR 1 - 5S :

    English Equivalent 'S'


    Japanese Term
    Translation term
    Seiri Organisation Sort
    Seiton Tidiness Systematise
    Seiso Cleaning Sweep
    Seiketsu Standardisation Standardise
    Shitsuke Discipline Self - Discipline
    PILLAR 2 - JISHU HOZEN ( AUTONOMOUS
    MAINTENANCE ) :

     Thispillar is geared towards


    developing operators to be able to
    take care of small maintenance tasks,
    thus freeing up the skilled
    maintenance people to spend time on
    more value added activity and
    technical repairs. The operators are
    responsible for upkeep of their
    equipment to prevent it from
    deteriorating.
    PILLAR 3 - KAIZEN :

     "Kai" means change, and "Zen" means good.

     This pillar aims at reducing losses in the


    workplace that affect our efficiencies.
    PILLAR 4 - PLANNED MAINTENANCE :

    PILLAR 4 - PLANNED MAINTENANCE :


    It is aimed to have trouble free machine and
    equipments producing defect free products
    for total customer satisfaction . Types :-
     Breakdown Maintenance

     Preventive Maintenance

     Corrective Maintenance

     Maintenance Prevention
    PILLAR 5 - QUALITY MAINTENANCE :

     QM activities is to set equipment conditions


    that preclude quality defects, based on the
    basic concept of maintaining perfect
    equipment to maintain perfect quality of
    products.
    PILLAR 6 - TRAINING :

     Phase 1 : Do not know.


    Phase 2 : Know the theory but cannot do.
    Phase 3 : Can do but cannot teach(skilled)
    Phase 4 : Can do and also teach. (expert).
    THE PEOPLE OF SUCCESSFUL
    TPM
    PILLAR 7 - OFFICE TPM :

     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 office
    automation.
    PILLAR 8 - SAFETY, HEALTH AND
    ENVIRONMENT

    Target :
     Zero accident,

     Zero health damage

     Zero fires.
    DIRECT BENEFITS OF
    TPM
     OEE up by 25-65%.
     Rectify customer complaints.

     Reduce the manufacturing cost by 30%.

     Satisfy the customers needs by 100 % .

     Reduce accidents.

     Follow pollution control measures.


    INDIRECT BENEFITS OF
    TPM
     Higher confidence level among the
    employees.
     Keep the work place clean, neat and
    attractive.
     Favorable change in the attitude of the
    operators.
     Achieve goals by working as team.

     Share knowledge and experience.

     The workers get a feeling of owning the


    machine.
    MAINTENANCE COSTS FULL COST
    VIEW
    Cost
    Total costs
    Full cost of
    breakdowns

    Preventive
    maintenance
    costs
    Optimal
    Maintenance
    Commitment

    24
    CONCLUSION:

     Today, with competition in industry at an all


    time high, TPM may be the only thing that
    stands between success and total failure for
    some companies.
     If everyone involved in a TPM program does
    his or her part, an unusually high rate of
    return compared to resources invested may
    be expected.
    REFERENCES:
     Wikipedia
     Journal of Industrial Engineering

     Industrial Engineering & Quality Maintenance

     www.scribid.co.in

     www.google.com
    THANK
    YOU.
    QUERIES
    ?????

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