TOTAL Productive MAINTENANCE ARVA IQBAL ROLL # 05 SANA MEHBOOB ROLL # 06 B.Sc.(Hons) Food Science and Technology 8th Semester (Regular)

CONTENTS Introduction History Why TPM Goals Purpose Principles of TPM Implementation steps Manufacturing losses

Maintenance Equipment improvement Process improvement Benefits Conclusion References Questions

INTRODUCTION TOTAL All individuals in the organization working together PRODUCTIVE Production of goods that meet customer expectations MAINTENANCE Keeping equipment and plant in good condition

INTRODUCTION (CONT…) Extension of TQM Set of activities for restoring equipment to its optimal condition Changing the work environment Improves productivity by making processes more reliable with minimum wastage Considered as medical sciences of machines

INTRODUCTION (cont.…) TPM is keeping current plant and equipment at its highest efficiency Good maintenance is fundamental to a productive maintenance system A productive maintenance implemented by all employees in an organization From operators to senior management in equipment improvement

HISTORY Innovative Japanese concept Developed in 1951 NIPPONDENSO was the 1st company to implement TPM in 1960 Company was awarded “the distinguished plant prize” for developing and implementing TPM, by the Japanese institute of plant engineers ( JIPE ) NIPPONDENSO became the first company to obtain the TPM certifications

WHY TPM Avoid wastage in quickly changing economic environment Producing goods with out reducing product quality Reduce cost for production Produce a low batch quantity at the earliest time Goods send to the customer must be non defective

Objectives of TPM The main objective of TPM is to increase the Overall Equipment Effectiveness of plant equipment  TPM addresses the causes for accelerated deterioration while creating the correct environment between operators and equipment to create ownership. OEE has three factors which are multiplied to give one measure called OEE Performance x Availability x Quality = OEE

OBJECTIVES OF TPM (CONT.…) Each factor has two associated losses making 6 in total Performance =(1) running at reduced speed (2) minor stops Availability  =(3) Breakdowns (4) Product changeover Quality  =(5) Startup rejects (6) Running rejects

GOALS Increase production Reduce manufacturing cost Improve production quality Continuous improvement Maintain accident free environment Job satisfaction Increasing employee morale Achieve 100 % success in delivering goods

PURPOSE TPM To upgrade the capabilities of all company members through To identify productivity losses Involve all members of the company in loss elimination programs Education Participation Training TPM LOSS

PRINCIPLES OF TPM Use Overall Equipment Effectiveness (OEE) as a compass for success Improve existing planned maintenance systems Work toward zero losses Providing training to upgrade operations and maintenance skills Involve everyone and utilize cross-functional teamwork

IMPLEMENTATION STEPS Perform initial cleaning and inspection Countermeasures for the causes and effects of dirt and dust Establish cleaning and lubrication standards Conducting general inspection training Carry out equipment inspection checks workplace management and controls Continuous improvement

Total manufac-turing losses(13%) Equip-ment losses (6%) Material losses (4%) Total manufac-turing losses(13%) Manpower losses (3%)

1)EQUIPMENT LOSSES Equipment failure/breakdown DOWNTIME LOSS . Equipment failure/breakdown DOWNTIME LOSS Setup and adjustments SPEED LOSS Reduced speed Minor stopping of function Process error QUALITY LOSS Rework

2)MANPOWER LOSSES Measurement & Adjustment Loss Management Loss Operating Motion Loss Line Organization Loss Logistics Loss

3)MATERIAL LOSSES 3 Major Losses Obstructing Material & Energy Utilization: Material yield Energy losses Tool and fixture loss

MAINTENANCE The management, control, execution and quality assurance of activities which ensure the achievement of optimum availability and performance of a plant in order to meet business activities

TYPES OF MAINTENANCE Maintenance prevention Breakdown maintenance Preventive maintenance Productive maintenance

TYPES OF MAINTENANCE (CONT...) a) Breakdown maintenance To set the machine right when in trouble and no care is taken until equipment fails b) Preventive maintenance It is daily maintenance (cleaning, oiling, inspection and re-tightening), design to retain the healthy condition of equipment and prevent failure

TYPES OF MAINTENANCE (CONT...) c) Corrective maintenance Improves equipment and its component. Equipment with design weakness must be redesigned to improve reliability and maintainability d) Total productive maintenance Indicates design of new equipment and observations and study made on weakness of current machines are shared with equipment manufacturer and necessary changes are made

PROCESS IMPROVEMENT New process needs to be Objectives Establish preventive and predictive maintenance system for trouble free equipment and tooling Natural life cycle of individual machine elements must be achieved New process needs to be correct operation correct set-up cleaning lubrication feedback and repair of minor defects quality spare parts

EQUIPMENT IMPROVEMENT Objective New equipment needs to be Easy to operate Easy to clean Easy to maintain and reliable Have quick set-up times Operate at the lowest life cycle cost New production or equipment development Start-up commissioning and stabilization time for quality and efficiency

DIFFERENCES B/W TQM AND TPM Quality (output and effects) Equipment (input and output) Systemize the management. Employees participation. Continuous improvement Elimination of losses and wastes

Increase productivity BENEFITS Increase productivity Job Security Improved Quality Improved Skills Reduce manufacturing cost

BENEFITS (CONT…) Rectify customer complaints Reduce accidents Safe and attractive Work Environment Achievement of goals Sharing of knowledge and skills

CONCLUSION TPM may be the only thing that stands between success and total . It can be adapted to work not only in industrial plants, but in construction, building maintenance, transportation, and in a variety of other situations provide framework to establish TPM. It should be modified to meet different organizational needs.

CONCLUSION (CONT…) An effective total productive maintenance program will lead to improved quality and productivity. Skilled techniques are utilized more effectively in doing major overhauls and assisting with troubleshooting problems. Goals should be set after the improvement needs are identified.