1. TOTAL PRODUCTIVE MAINTENANCE
BY AMAR P. NARKHEDE

2. INTRODUCTION
TPM based on zero loss concept, zero accidents, zero defects and zero breakdowns which renders equipments highly effective
Total productive maintenance
Aims at getting efficient use of equipments means overall efficiency
Promotes and implements productive maintenance through group or team activities
TPM is deployed through a unique 8 pillar approach for easy deployment in any industry at any age

3. 8 PILLARS OF TPM Autonomous maintenance (JISHU-HOZEN) KOBETSU- KAIZEN
Planned maintenance
Quality maintenance
Maintenance prevention and equipment initial control
Education and training
Safety health and environment
Office TPM

4. Autonomous maintenance (JISHU-HOZEN)
Autonomous maintenance is the cleaning, checking, discovering hidden faults and undertaking simple adjustments by operators, systematically trained through a step by step program. Autonomous management is to prevent reoccurrence of defects by taking preemptive action by the operator. This is my machine and must maintain it this should be the attitude of every operator

5. Kobetsu- kaizen: It is continuously improve workers, equipments and material through continuous improvement in the process and procedure. It analyses various causes of time losses and evolves solutions to chronic problems like
Breakdown losses
Setup and adjustment losses
Speed losses
Quality defects and rework loss
Start up losses

6. Benefits of Kobetsu Kaizen
Equipment failures
Equipment breakdowns
Job change time
Tool change time
Minor stops
Management losses
a. want of operators
b. want of tools materials
7. Manufacturing costs

7. Planned maintenance:
Planned maintenance is to achieve zero breakdown by improving the efficiency of traditional preventive maintenance activities
Planned maintenance aims at
Focusing on planned maintenance rather than breakdown maintenance
Achieving autonomous maintenance
Supporting autonomous maintenance
Increasing meantime between failure MTBF
Reducing maintenance cost

8. Quality maintenance:
Quality maintenance is to prevent defects in quality by
Incorporating quality into products through process and equipment rather than controlling quality by inspecting products and taking action against defects after they have occurred
Maintaining perfect machine and tooling conditions so that defects are not produced
Setting and maintaining optimal process conditions to get quality products
Preventing occurrence of defects by periodic measurements and verification of standards
Taking counter measures

9. Maintenance prevention design and initial equipment control:
M.P. design and initial equipment control is designed to facilitate
Most efficient equipment investment aimed at achieving a vertical start upon full production
Design of equipment which is functional, easy and which does not fail
Shorten the period of development
Achieve low life cycle of equipment

10. Education and Training:
It is the one of the important pillar of TPM since success of TPM depends on the Education and Training. The aim of education and Training is
To develop talent in equipment maintenance and operation
To develop skills for zero defects, zero break down and zero accidents
To develop abilities to discover and analyze malfunctions and improve equipment functioning
To have multi-skilled employees in all department

11. Office TPM:
Office TPM is to eliminate problems in the non stop floor activity so that offices are oriented for excellent support for manufacturing. Typical office problems analysis under office TPM are: non availability of files/documents in time, lengthy meeting without agenda, poor housekeeping, insufficient storage, high inventory, slow manual working, duplicate work. TPM aims at:
Improvement in the filing system
Paperless working
Office automation
Reduction in product inventory
Increase in office productivity
Speedy communication

12. Safety, hygiene and environment control:
Safety, hygiene and environment control is to identify and eliminate all hazards by adopting safe, hygiene and environment friendly activities to prevent death, disability, injuries and occupational diseases at work
TPM is one of the best tools to enhance safety and environment at the work place through small group activities and involvement at all levels of the organization for the common goal of zero accidents and zero pollution
TPM aims at
Zero accidents
Zero occupational disease
Zero pollution

13. TWELVE STEPS PROCEDURES FOR IMPLEMENTATION OF TPM
Declaration by top management to introduce TPM
Introductory education and campaign for TPM
Create organizations to promote TPM
Setting basic policy and targets for TPM
Preparation of master plan for implementing TPM
TPM kicks off projects in the organization
Steps 7 to 11 implementation of all 8 TPM pillars
Total application of TPM and raising its level

14. BENEFITS OF TPM Greater equipment availability Low production cost
Development of employees
Great employee involvement due to small group activities
Improved quality
Few customers complaints

15. THANK YOU