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

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

4. Maintenance
Equipment improvement
Process improvement
Benefits
Conclusion
References
Questions

5. 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

6. 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

7. 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

8. 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

9. 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

10. 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

11. 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

12. 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

13. 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

14. 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

15. 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

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

17. 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

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

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

20. 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

21. TYPES OF MAINTENANCE Maintenance prevention Breakdown maintenance
Preventive maintenance
Productive maintenance

22. 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

23. 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

24. 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

25. 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

26. 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

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

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

29. 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.

30. 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.