TOTAL PRODUCTIVE MAINTENANCE CONCEPTS 29 TH JANUARY 2011 RM PERIYANNAN MANAGER(MECHANICAL) SERVICES MECHANICAL

WHAT IS TPM TPM IS A MAINTENANCE PROGRAM CONCEPT. IT IS NOT REGARDED AS NON PROFIT ACTIVITY. MAINTENANCE DOWNTIME IS SCHEDULED AS MANUFACTURING DAY AND IN SOME CASES INTEGRAL PART OF MANUFACTURING PROCESS. THE GOAL IS TO REDUCE THE EMERGENCY AND UNEXPECTED BREAKDOWN. TPM IS EVERYONE’S PARTICIPATION.

FIVE PILLARS OF TPM  TPM Autonomous Maintenance  Maintenance Process Improvement  Systematic Equipment Improvement  Training & Skill Development  Early Equipment Management Cross-Functional, Team-Based Improvement Activities

OBJECTIVES OF TPM  ZERO UNEXPECTED DOWNTIME  ZERO DEFECTS  ZERO LOSSES  ZERO ACCIDENTS

PRINCIPAL CHARACTERISTICS OF TPM  OPERATORS PERFORM PREVENTIVE MAINTENANCE.  SKILLED MAINTENANCE PERSONNEL TO TRAIN AND DEVELOP THE OPERATORS.  MAINTENANCE DEPARTMENT MOVES FROM”FIRE FIGHTING “ MODE TO PREVENTION MODE AND RE ENGINEERING.

GOALS OF TPM  TO OBTAIN MOST EFFICIENT USE OF ALL PRODUCTION EQUIPMENTS.(OEE)  TO ESTABLISH A TOTAL PM SYSTEM i.e., PREDICTIVE,PREVENTIVE AND IMPROVEMENT RELATED MAINTENANCE.  FULL PARTICIPATION OF DESIGNERS,OPERATORS AND MAINTENANCE DEPARTMENT PERSONNEL.

GOALS OF TPM (Contd..)  INVOLVING ALL EMPLOYEES FROM TOP TO FRONT LINE WORKERS.  PROMOTING ALL THROUGH MOTIVATION i.e.., THROUGH AUTONOMOUS SMALL GROUP ACTIVITIES.

TYPES OF PM  PREVENTIVE MAINTENANCE  PREDICTIVE MAINTENANCE  PERIODIC MAINTENANCE

ANOTHER PM  THAT IS POSTPONED MAINTENANCE WHICH RESULTS IN  UNEXPECTED EQUIPMENT BREAKDOWNS  CYCLE TIME INCREASES  PRODUCTION LOSS

PARADIGM SHIFT OLD FASHIONED ACTIVITYAPPROACH I OPEARTE, YOU FIXWE ARE ALL RESPONSIBLE FOR OUR EQUIPMENT. I FIX YOU DESIGN I DESIGN YOU OPERATE

TYPES OF HEMM  PRODUCTION EQUIPMENTS DRILLS,EXCAVATORS,DUMPERS,FRONT END LOADER ETC.,  SERVICE EQUIPMENTS : BULL DOZERS,MOTOR GRADERS,WATER SPRINKLERS,JCB ETC.,

 BREAKDOWN MAINTENANCE  ROUTINE MAINTENANCE  PLANNED MAINTENANCE  PREVENTIVE MAINTENANCE  PREDICTIVE MAINTENANCE  OVERHAULING  RECONDITIONING  REFURBISHING( NEW TECHNOLOGY UPGRADATION) AND  EQUIPMENT REPLACEMENT

OBJECTIVES OF MAINTENANCE MANAGEMENT  ENSURE MAXIMUM AVAILABILITY OF PLANT AND EQUIPMENT AT OPTIMUM OPERATIONAL LEVEL.  TO INCREASE THE LIFE SPAN OF EQUIPMENTS.  ENSURE SAFETY TO PERSONNEL AND EQUIPMENT

OBJECTIVES OF MAINTENANCE MANAGEMENT  IDENTIFY AND IMPLEMENT PROCESS IMPROVEMENTS/COST REDUCTION.  MINIMIZE ENERGY/UTILITIES USAGE.  MINIMIZE INVENTORY COST.  MAINTAIN ACCURATE AND UPTO DATE MAINTENANCE RECORDS.

FAILURE ANALYSIS  STRESS RELATED DUE TO OPERATIONAL AND EVNVIRONMENTAL FACTORS.  INFERIOR QUALITY OF RAW MATERIAL USED.  OVERLOOKING OR NOT LOOKING DEFECTS IN MAUFACTURING.  NORMAL WEAR AND TEAR.  OPERATIONAL ERRORS.  POOR MAINTENANCE.

THREE STEPS TO MEET CHALLENGE  1. MAINTENANCE STRATEGY  2.MAINTENANCE SERVICE IMPROVEMENT  3. MAINTENANCE PLANNING.

DETERMINATION OF MAINTENANCE STRATEGY CORPORATE STRATEGY MAINTENANCE OBJECTIVES MANUFACTURING STRATEGY

MAINTENANCE OBJECTIVES MAINTENANCE STRATEGY WITH REGARD TO MANPOWER,SKILL, TOOLS,GADGETS,SPARE PARTS,WORKSHOP FACILITIES,DOCUMENTATION AND PLANNING

MAINTENANCE SERVICE IMPROVEMENT  ENGINEERING  BENCH MARKING  VALUE ANALYSIS  RE ENGINEERING

PLANNING AND CONTROL RESOURCES  MANPOWER: HRD,TRAINING,WORK SAMPLING,INCENTIVES.  MACHINES: PLANT LAYOUT, DIFFERENT TYPES OF MAINTENANCE(TPM ETC.,)  MATERIALS:INVENTORY CONTROL  ENERGY:CONSERVATION  FINANCE : COST CONTROL

CONCLUSION  THE EXIGENCIES OF PRODUCTION IS ALWAYS IMPORTANT BUT AT THE SAME TIME MAINTENANCE CANNOT BE PUSHED TO BACKWATERS.  ADEQUATE ATTENTION TO MAINTENANCE PRACTICE SHALL IMPROVE THE MAXIMUM UTILIZATION OF EQUIPMENTS AND MORE PRODUCTIVITY.

WISH YOU ALL A GOOD LUCK THANK YOU