TOTAL PRODUCTIVE MAINTENANCE.

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Presentation transcript:

TOTAL PRODUCTIVE MAINTENANCE

Definition Maintenance is defined as 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 objectives.

TPM - Meaning TPM is a partnership between the maintenance and production organization to improve product quality, reduce waste, reduce cost, increase equipment availability and improve maintenance state.

EVOLUTION OF MAINTENANCE First Generation Second Generation Third Generation Fix it when it broke Higher plant availability Longer equipment life Lower Costs Higher plant reliability and availability Greater safety Better quality Cost Effectiveness 1940 1950 1960 1970 1980 1990 2000

TYPES OF MAINTENANCE Corrective (or) breakdown maintenance It implies that repairs are made after failure of machine or equipment Scheduled (or) Routine maintenance It is a stitch-in-time procedure aimed to avoiding breakdowns

TYPES OF MAINTENANCE Preventive maintenance It is carried out before the failure arises (or) prior to the equipment actually breakdowns. E.g. Overhauling & Periodic upkeep. Predictive maintenance Equipment Condition evaluated periodically and maintenance carried out.

OBJECTIVES OF TPM Improve Equipment Effectiveness Achieve Autonomous Plan Maintenance To Train all staff in maintenance skills To Zero Breakdowns

Cost Trade-off Between PM & CM 1000 C o s t i n R u p e 650 Total cost of maintenance Maintenance Activity Costs (PM) 500 Breakdown Penalty costs (CM) 50 LOW MEDIUM MAINTENANCE HIGH

BIG LOSSES 1. Breakdowns Long interruptions, Costly Repairs 2. Setup and changeover Taking Longer time than needed 3. Idling time and stoppages Hard to quantify, add to big losses 4. Reduced speed Equipment cycle time reduces 5. Defects and reworks Quality losses & Unhappy customer

BENEFITS Increased productivity Equipment reliability Reduced down time Increased plant capacity Low production maintenance costs Team work Between Production & Maintenance People Improved safety & Profit

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