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Otal Roductive Aintenance: Designed by Danish Zakria Hafiz Abdul Manan

The document discusses Total Productive Maintenance (TPM) which aims to increase production while improving employee morale. It does this through minimizing breakdowns and implementing pillars like autonomous maintenance (Jishu Hozen) where operators perform small maintenance tasks, planned maintenance to have trouble-free equipment, quality maintenance to reduce defects, and training to improve employee skills. The pillars are introduced in companies through preparatory education and setting up committees before implementation and institutionalization of TPM.

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Manan IFtikhar
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158 views11 pages

Otal Roductive Aintenance: Designed by Danish Zakria Hafiz Abdul Manan

The document discusses Total Productive Maintenance (TPM) which aims to increase production while improving employee morale. It does this through minimizing breakdowns and implementing pillars like autonomous maintenance (Jishu Hozen) where operators perform small maintenance tasks, planned maintenance to have trouble-free equipment, quality maintenance to reduce defects, and training to improve employee skills. The pillars are introduced in companies through preparatory education and setting up committees before implementation and institutionalization of TPM.

Uploaded by

Manan IFtikhar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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TOTAL

PRODUCTIVE
MAINTENANCE
Designed By
Danish zakria
Hafiz Abdul Manan
TOTAL PRODUCTIVE MAINTENANCE ….

GOAL
2. Increase production while,
at the same time, increasing
employee morale and job
satisfaction.

2. Hold emergency &


unscheduled maintenance to
a minimum.

0
8
TOTAL PRODUCTIVE MAINTENANCE

TYPES OF MAINTENANCE
Breakdown Maintenance
Preventive Maintenance
a). Periodic Maintenance
b). Predictive Maintenance
Corrective Maintenance
Maintenance Prevention
TOTAL PRODUCTIVE MAINTENANCE

Motives of TPM
b) Adoption of Life – Cycle approach for improving the overall
performance of production equipments
c) Improving Productivity by highly motivated workers which
is achieved by Job – Enlargement
d) Formation of team of volunteers for activities viz, cause of
failure, possible reduction of cycle time; and equipment /
process modifications.
Uniqueness of TPM
The major difference between TPM and other concepts is that the
operators are also made to involve in the maintenance process.
TOTAL PRODUCTIVE
MAINTENANCE
Introducing TPM at a Production Unit

STEP – 1. Preparatory Stage


 Announcement by TOP MANAGEMENT to all
about TPM introduction in the organization
 Initial education and publicity for TPM
 Setting up TPM & Departmental committees
 Establishing the TPM working systems & target
 A master plan for institutionalizing
STEP – 2. Introduction Stage
STEP – 3. Implementation
STEP – 4. Institutionalizing
Stage
TOTAL PRODUCTIVE MAINTENANCE ….
PILLARS OF TPM

PILLAR :JISHU HOZEN


(Autonomus Maintenance)
This pillar is geared towards developing
Operators to be able to take care of
small maintenance tasks, thus freeing
up skilled maintenance people to
spend time on more value added
activity and technical repairs. The
operators are responsible for up keep
of their equipment to prevent it from
deteriorating.
TOTAL PRODUCTIVE MAINTENANCE ….
PILLARS OF TPM

PILLAR 2 :JISHU HOZEN….


POLICY
Uninterrupted operation of equipments
Flexible operators to operate & maintain other equipments
Eliminating the defects at source through active employee
participation Stepwise implementation of JISHU HOZEN activities.
JH TARGETS
Reduce process time by ………%
Reduce oil/ lubricants consumption by ………..%
Increase use of JH
JH STEPS
Preparation of employees
Initial cleanup of machines
Take counter measures
Fix tentative JH standards
General inspection
Autonomus inspection
Standardization
Autonomus management
TOTAL PRODUCTIVE MAINTENANCE ….
PILLARS OF TPM

PILLAR : PLANNED MAINTENANCE


It is aimed to have trouble free machines and equipments producing
defect free products for total customer satisfaction.

With planned maintenance, we evolve an effort from a reactive to a


proactive method and use trained maintenance staff to help train the
operators to better maintain their equipment.

Policy:

 Achieve and sustains availability of machines


 Optimum maintenance cost.
 Reduce spares inventory.
 Improve reliability and maintainability of
machines.
TOTAL PRODUCTIVE MAINTENANCE ….
PILLARS OF TPM

PILLAR : PLANNED MAINTENANCE….


TARGET:
1. Zero equipment failure and breakdown.
2. Improve reliability and maintainability by 50%.
3. Reduce maintenance cost by 20%.
4. Ensure availability of spares all the time.

STEPS:
 Equipment evaluation and recording present status.
 Restore deterioration and improve weakness.
 Building up information management system.
 Prepare time based information system, select equipment, parts and
members and map on the plan.
 Prepare predictive maintenance system by introducing equipment
diagnostic techniques and
 Evaluation of planned maintenance.
TOTAL PRODUCTIVE MAINTENANCE ….
PILLARS OF TPM

PILLAR : QUALITY MAINTENANCE (QM)…


TARGET:
Achieve and sustain customer complaints at zero.
Reduce in-process defects by 50%.
Reduce cost of quality by 50%.

DATA REQUIREMENTS:

Quality defects are classified as “CUSTOMER END DEFECTS” and


IN HOUSE defects. For customer-end data, we have to get data on

1. Customer end line rejection


2. Field complaints

In-house data include data related to products and data related to


process.
TOTAL PRODUCTIVE MAINTENANCE ….
PILLARS OF TPM

PILLAR : TRAINING….

POLICY :
Focus on improvement of knowledge skill & techniques.
Creating a training environment for self learning based on felt needs.
Training curriculum/tools/assessment etc. Conductive to employees’
revitalization.
Training to remove employee fatigue and make work enjoyable.

TARGET:
Achieve and sustain downtime due to want men at zero on critical
machines.
Achieve and sustain zero losses due to lack of
knowledge/skills/Techniques
Aim for 100% participation in suggestion scheme.

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