Dr. S. Poornachandra Dean EIE & BME SNS College of Technology TOTAL PRODUCTIVE MAINTENANCE Dr. S. Poornachandra Dean EIE & BME SNS College of Technology

OBJECTIVE Create a system in which all maintenance activities can be planned and not interfere with the production process Surprise breakdown should not occur

TOTAL PRODUCTIVE MAINTENANCE Keeping the current plant & equipment at its highest productive level through cooperation of all areas of the organization Predictive Maintenance Estimating breakdown of the equipment based on the data & Statistical tools Preventive Maintenance Periodic maintenance activities such as lubrication etc.

GOALS OF TPM Maintenance & Improving equipment capacity Maintaining equipment for life Using support from all areas of the operation Encouraging input from all employees Using teams for continuous improvement

LOSSES PLANNED LOSSES UN-PLANNED LOSSES Start-ups Shift changes Coffee & lunch breaks Planned maintenance shutdowns Equipment breakdown Changeover Lack of materials

OTHER LOSSES Reduced speed losses Poor quality losses Idling & Minor stoppages Slow-downs Poor quality losses Process nonconformities scrap

LOSE CALCULATION Downtime losses Reduced speed losses A = Availability; T = Operating time (P-D); P = Planned operating time; D = Downtime Reduced speed losses E = Performance efficiency; C = Theoretical cycle time; N = Processed amount (quantity) Poor quality losses R = rate of quality products; Q = nonconformitives Equipment effectiveness EE = equipment effectiveness; OEE = overall equipment effectiveness