Semester 8th (Self Support) Sania Sheikh (31) Iqra Khan (32) B.Sc. (Hons). Food Science and Technology Semester 8th (Self Support) INSTITUTE OF FOOD SCIENCE AND NUTRITION UNIVERSITY OF SARGODHA, SARGODHA

CONTENTS Definition Goal Employees Machines Types of maintenance Steps for implementation OEE in TPM 8 pillars References

DEFINITION “System to maintain + improve Quantity + Quality Of machines Equipments Process Employees”

GOAL Enhance Volume of production Employee morale

EMPLOYEE

Develop team spirit

MACHINES

Types of Maintenance Breakdown maintenance Preventive maintenance Corrective maintenance Maintenance prevention

Breakdown maintenance Repair the equipment when it fails Preventive maintenance Daily maintenance like oiling, cleaning, re-tightening for prevention of failure

Corrective maintenance Improvement of equipment design and components Maintenance Prevention Indicates the design of new equipment + its comparison with old ones

STEPS FOR IMPLEMENTATION Initial evaluation of TPM level of an organization Introductory education and propaganda (IEP) for TPM Form TPM committee Development of master plan for TPM Stage by stage training of employees

6. Implementation preparation 7. Establish TPM policies and goal 8 6. Implementation preparation 7. Establish TPM policies and goal 8. Development of a road map for TPM implementation

OEE IN TPM It measures how productive a process is against the expected productivity of that process Availability Performance Quality

8 Pillars

8 PILLARS Autonomous maintenance Planned maintenance Quality maintenance Focused improvement Early equipment maintenance Education and training Health, safety and environment TPM in office functions

Pillar 1:Autonomous Maintenance Responsibility of basic maintenance activities Benefits Operators feel responsible towards machines equipment becomes more reliable Skill levels of workers improve Machines operate at their optimal level Problems are identified and corrected

Pillar 2:Planned Maintenance Maintenance scheduled using the historic failure rate of equipment Benefits The number of breakdowns gradually decrease Production functions can continue with their activities Capital investments in machinery are reduced Maintenance is done when the production floor is not very busy

Pillar 3:Quality Maintenance Quality ingrained in the equipment so as to reduce defects Addresses the issue of quality by ensuring equipment is able to detect and prevent errors during production It helps in preventing defects from moving down the value chain which only leads to a lot of rework Benefits Defect reduction First time right Profit improvement

Pillar 4: Focused Improvement Use of cross-functional teams for improvement activities Benefits Wide range of experienced people involved Improves problem solving capabilities of the workers

Pillar 5: Early Equipment Maintenance Design of new equipment using lesson learnt from previous TPM activities Benefits Ease of cleaning and inspection Ease of lubrication Accessibility of equipment parts Increased safety features New equipment achieves full potential in a short period of time

Pillar 6: Education and Training Bridge the skills and knowledge gap through training of all workers Through training, operators’ skills levels are raised to the point where they are able to carry-out basic maintenance activities The technical staff are then taught higher level skills to help become more proactive to problem solving Benefits Employees gain the skills to solve problems

Pillar7:Health,safety and Environment Providing of an ideal working environment devoid of accidents and injuries Benefits Elimination of harmful conditions Workers attitude towards work changes with a resultant increase in productivity

Pillar 8: TPM in office functions Spread of the principles to administrative functions within an organization Benefits Support functions understand the benefits of these improvements

REFERENCES https://en.wikipedia.org/wiki/Total_productive_maintenance http://www.plant-maintenance.com/articles/tpm_intro.shtml