TPM is a productive maintenance implemented by

all employees in an organization.

TPM involves everyone in the organization from

operators to senior management in equipment
improvement.
Total = All individuals in the organization
working together.

Productive = production of goods that meet or

exceed customer’s expectations.

Maintenance = keeping equipment and plant in

good condition at all times.
 This is an innovative Japanese concept.
 Developed in 1951.
 Nippondenso was the 1st company that
implemented TPM in 1960.
 Based on these developments Nippondenso
was awarded the distinguished plant prize for
developing and implementing TPM, by the
Japanese Institute of Plant Engineers ( JIPE ).
 This Nippondenso became the first company
to obtain the TPM certifications.
 Increase production quality.

 Increase job satisfaction.

 Using teams for continuous improvement.

CONTINUOUS PROCESS IMPROVEMENT

 Improve the state of maintenance

 Empower employees
 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.
 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
Are . . . .

u Hidden causes of problems

u Seeds

8
Physical: u Not Visible
u Need To Disassemble
u Hidden Behind
u Covered By Dust, Stains, Etc.

Psychological: u Left Ignored Because Of Lack of

Interest Or Skill
u Operator & Maintenance
Indifference
u Not Familiar With The Defect
u Error In Judgement Of The
Defect

9
Function Stoppage: Failure causing the
equipment to stop
completely.

Function Deterioration: Equipment function is not

fully utilized and is
beginning to malfunction
by minor stoppages.

10
We must change our way of
thinking to realize that the
equipment can be protected
from failure.

Equipment

Failure

11
ÜDiscover latent defects to prevent failures
“Failure” is only
the tip of the
iceberg

FAILURE

LATENT DEFECTS

Dust, soiling, adhesion of raw materials.

Abrasion, backlash, looseness, leaks
Corrosion, deformation, flaws, cracks
Temperature, vibration, sound, and other errors
12
1. Establish Basic Conditions
2. Maintain Operating Conditions
3. Restore Equipment From A Deteriorated State
4. Improve Weak Points Of Design
5. Upgrade The Skill Level

13
1. Establish Basic Conditions Loss Elimination

Operator Autonomous
2. Keep Operating Conditions Maintenance

Restore Equipment
3. From A Deteriorated Planned Maintenance
State

Improve Weak Points

4. Education And Training
In Design

5. Improve The Skill Level Initial Flow Control Of

Equipment

14
u 5 Major Losses Obstructing
Manpower Efficiency

u 3 Major Losses Obstructing Material

& Energy Utilization

u 8 Major Losses Obstructing

Equipment Efficiency

15
5 Major Losses Obstructing Manpower Efficiency:

1. Management Loss
2. Operating Motion Loss
3. Line Organization Loss
4. Logistics Loss
5. Measurement &
Adjustment Loss

16
3 Major Losses Obstructing Material & Energy Utilization:

1. Energy Loss
2. Die, Tool, & Fixture Loss
3. Material Loss

17
8 Major Losses Obstructing Equipment Efficiency:

1. Equipment Failure Loss: Largest failure of all losses.

Two types:
a. Function-Stoppage:
Failure occurs unexpectedly
b. Function-Deterioration:
Decreases over time

2. Set-Up & Adjustment Loss

Set-Up: Losses due to changeover
Adjustment: Minor process adjustments

18
 8 Major Losses Obstructing Equipment Efficiency:
3. Consumable Parts Change Loss: Weld tip, weld liners,
cutting bits

4. Start-Up Loss: Equipment warm-up

and stabilization

5. Minor Stoppage & Idling Loss: Losses we have a tendency

to “put up with”
- part hanging
- pushing re-set button

19
8 Major Losses Obstructing Equipment Efficiency:

6. Speed Loss: Slowing the equipment

down to produce good
quality

7. Defect & Rework Loss: Time and manpower lost

in both types

8. Shutdown Loss: Planned stoppage of

equipment

20
 Breakdown maintenance

 Preventive maintenance

.periodic maintenance( time based maintenance)

.Predictive maintenance

 Corrective maintenance

 Maintenance prevention
 Repairs or replacements performed after a
machine has failed to return to its functional
state following a malfunction or shutdown.
 e.g., an electric motor of a machine tool will not
start, a belt is broken, etc.
 Under such conditions, production department
calls on the maintenance department to rectify
the defect.
 After removing the fault, maintenance engineers
do not attend the equipment again until another
failure or breakdown occurs.
 The primary goal of preventive maintenance
is to prevent the failure of equipment before
it actually occurs.
 It is designed to preserve and enhance
equipment reliability by replacing worn
components before they actually fail.
 It is a daily maintenance which includes
cleaning, inspection, oiling and re-tightening
of equipments.
 Improved system reliability.

 Decreased cost of replacement.

 Decreased system downtime.

 Better spares inventory management.

 Time based maintenance consists of
periodically inspecting, servicing and cleaning
equipment and replacing parts to prevent
sudden failure and process problems.

Benefits:

 Extended life and use of the equipment.

 Reliable production at the times when

machine is needed most.
 This is a method in which the service life of
important part is expected based on
inspection or diagnosis, in order to use the
parts to the limit of their service life.

 Compared to periodic maintenance,

predictive maintenance is condition based
maintenance.
 Increased plant readiness due to greater
reliability of the equipment.
 Many industries report from two to ten
percent productivity increases due to
predictive maintenance practices.
 Reduced expenditures for spare parts and
labor.
 Reduces the probability of a machine
experiencing a disastrous failure, and this
results in an improvement in worker safety.
 Maintenance actions carried out to restore a
defective item to a specified condition
 Corrective maintenance is probably the most
commonly used approach, but it is easy to see its
limitations.
 When equipment fails, it often leads to downtime
in production.
 In most cases this is costly business. Also, if the
equipment needs to be replaced, the cost of
replacing it alone can be important.
 It is also important to consider health, safety and
environment (HSE) issues related to
malfunctioning equipment.
 It indicates the design of a new equipment.

 Weakness of current machines are sufficiently

studied ( on site information leading to failure
prevention, easier maintenance and prevents
of defects, safety and ease of manufacturing )
and are incorporated before commissioning a
new equipment.
 Based on five Japanese words that begin with
‘S’, the 5S Philosophy focuses on effective
work place organization and standardized
work procedures.
5 S’s
1. Sort :(Seiri)  Rapi
2. Set In Order:(Seiton)  Rajin
3. Shine: (Seiso)  Resik
4. Standardize: (Seiketsu)  Ringkas
5. Sustain: (Shitsuke)  Rawat
 The first S focuses on eliminating
unnecessary items from the workplace.
 An effective visual method to identify these
unneeded items is called red tagging.
 A red tag is placed on all items not required
to complete your job. These items are then
moved to a central holding area.
 This process is for evaluation of the red tag
items.
 second S focuses on efficient and effective
storage methods and how to organize the
work area.
 Strategies for effective Set In Order are
painting floors, outlining work areas and
locations, shadow boards, and modular
shelving and cabinets for needed items such
as trash cans, brooms, mop and buckets
 Once you have eliminated the clutter and junk
that has been clogging your work areas and
identified the necessary items, the next step
is to thoroughly clean the work area.
 Workers will also begin to notice changes in
equipment and facility location such as air,
oil, coolant leaks, fatigue, breakage, and
misalignment.
 These changes, if left unattended, could lead
to equipment failure and loss of production.
 Now the first three S’s are implemented.
 Use standard methods to keep Sort, Set In
Order, and Shine to a condition .
 Allow your employees to participate in the
development of such standards.
 This is the most difficult S to implement and
achieve.
 Maintain through empowerment,
commitment, and discipline .
 Sustain focuses on defining a new status quo
and standard of work place organization.
 Simplifies work environment
 reduces waste
 Improves quality
 Improves safety
 Provide self esteem for everyone in the
organization.
 Total commitment to the program by upper
level management is required in both
programs.
 Employees must be empowered to initiate
corrective action, and
 A long range outlook must be accepted, as
TPM may take a year or more to implement.
 It is an on-going process which is a
continuous process improvement.
 Category TQM TPM

Object Quality ( Output and Equipment ( Input and

effects ) cause )

Systematize the Employees participation

Mains of attaining goal management. It is and it is hardware
software oriented oriented

Target Quality for PPM Elimination of losses

and wastes.
 PILLARS of TPM

1 2 3 4 5 6

7
8
 Train the operators to close the gap
between them and the maintenance staff,
making it easier for both to work as one
team
 Change the equipment so the operator can
identify any abnormal conditions and
measure before it affects the process or
leads to a failure
Seven (7) steps are implemented to
progressively increase operators
knowledge, participation and
responsibility for the equipment.
1. perform initial cleaning and inspection
2.Countermeasures for the causes and effects of
dirt and dust
3.Eastblish cleaning and lubrication standards
4.Counducting general inspection training
5.Carry out equipment inspection checks
6.workplace management and controls
7.Continious improvement
Outside Source Support Training
uScrews, Bolts, & Fasteners
uEquipment Safety
OIL uLubrication

uHydraulics

uPneumatics

uDrive Systems
uElectrical Systems
uMachine Systems
43
Objectives: Maximize efficiency by
eliminating waste and manufacturing loss
Manufacturing losses are categorized into 13
bid losses:

Equipment losses (6)

Manpower losses (4)

Material losses (3)

u Design
u Manufacturing
u Installation
u Operation
u Maintenance

45
. . Equipment failure / breakdowns
DOWNTIME LOSS
Set-up / adjustments

Minor stopping
Speed loss
Reduced speed

Process errors
Quality loss
Rework / scrap
 . Cleaning and checking

Waiting materials
Manpower losses
Waiting instructions

Waiting quality confirmation

Material yield

Material losses Energy losses

 OEE figures are determined by combining
the availability and
performance of your equipment with the
quality of parts made

 OEE measures the efficiency of the machine

during its loading time.
Planned downtime does not effect the OEE
figure
 .
Overall equipment effectiveness = Availability * performance * Quality yield

Availability Downtime loss

Performance Speed loss

Quality Yield Quality loss

  .
Overall Equipment Effectiveness = Availability *performance * Quality yield

Availability = Time available for production -- Downtime

Time available in production

Performance = Ideal cycle time * number of parts produced

Operating time

Quality Yield = total number of parts produced – defect number

Total number of parts produced
Objectives : Establish preventative and predictive
maintenance system for equipment and tooling
 Natural life cycle of individual machine
elements must be achieved
 correct operation
 correct set-up
 cleaning
 lubrication
 feedback and repair of minor defects
 quality spare parts
Objective: establish system to shorter
new production or equipment development
start-up, commissioning and stabilization
time for quality and efficiency
New equipment need 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
Definition: a process for controlling the
condition of equipment components that affect
variability in product quality
Objectives: to set and maintain condition to
accomplish zero definition
Quality rate has direct correlation with

 material condition
 equipment precision
 production methods
 process parameters
 Administration and support departments
can be seen as process plans whose
principles tasks are to collect, process and
distribute information.

 Process analysis should be applied to

streaming information flow
TPM is a continuous learning process
Two major components :
 soft skills training : how to work as a
team, diversity training and communication
skills
 Technical training : upgrading problem-
solving and equipment-related skills
 Assuring safety and preventing adverse
environment impacts are important priority
in ant TPM effort
 Increasing motivation: changing people
attitudes
 Increasing competency and people skills
 Improving the work environment, so that it
support the establishment of a program for
implementing TPM
  . Announcement to TQM introduction
preparation Introductory education campaign for workforce
TPM promotion
Establish basic TPM policies and goals
Preparation and formulation of a master plan

Kick-off Invite customers, attitude companies and subcontractors

Develop an equipment management program

Develop a plan maintenance program
implementation Develop a Autonomous maintenance program
Increasing skills of production and maintenance personals
Develop early equipment management program

Stabilization Perfect TPM implementation and raise TPM levels

 State TPM objectives in a company
newsletter
 Place articles on TPM in a company
newspaper
 Seminars for managers
 Slide presentation for all employs
 Special committees at every level to
promote TPM
 Newsletter
 Articles
 Videos
 Posters
 Analyze existing conditions
 Set goals
 Predicting results
 A master plan lays out your goals, what you
will do to achieve them and when you will
achieve them
 Detailed plans for each pillar have to be
prepared
 The main kick-off to TPM should take the
form of a formal presentation with all the
employees attending
 This opportunity can be used to gain the
full support of the employees
 Invite external customers, affiliation and
subcontracting companies
 The principle of designing for maintenance
prevention can be new products, and to new
existing machines
 New products: must be designed so that they
can be easily produced on new existing
machines
 New machines : must be designed for easier
operation, changeover and maintenance
 Existing machines:
 Determine how to eliminate the problem and
reduce maintenance through an equipment
design change or by changing the process
 Increase equipment productivity
 Reduced equipment downtime
 Increased plan capacity
 Lower maintenance and production cost
 Approaching zero equipment-caused
defects
 Enhance job satisfaction
 Increase return on investment
Instructions
 Step1
Stand in a circle with a group of at least four people.
 Step2
Use your right hand to grab the right hand of the
person directly across from you.
 Step3
Use your left hand to grab the left hand of the person
to the right of the person holding your other hand.
 Step4
Untangle, as a group, back into one open circle,
without letting go of hands or dislocating any joints.
A. Total problem maintenance
B. Total process maintenance
C. Total productive maintenance
D. Time process management
 c
Total productive maintenance
A. Japanese concept
B. Chinese concept
C. American concept
D. Indian concept
 A
Japanese concept
A. Microsoft
B. Sun Microsystems
C. Chunlan Group Corp
D. Nippondenso
 D
Nippondenso
A. Predictive maintenance
B. Periodic maintenance
C. Breakdown maintenance
D. Preventive maintenance
 C
Breakdown maintenance
a) A=(t/p)*100

b) A=(p/t)*100

c) A=((d-p)/d)*100

d) A= (t/d)*100
 a
A=(t/p)*100
a) E=((D*N)/T)*100

b) E=(D/T)*100

c) E=((C*N))/T)*100

d) E=(R/T)*100
 C
E=((C*N))/T)*100
a. R= (Q/N)*100

b. R=(N-Q)/N *100

c. R= (T/N)*100

d. R=(C/T)*100
 b
R=(N-Q)/N *100
a. EE= A/E*R

b. EE=E/A*R

c. EE=A*E*T

d. EE=A*E*R
 d
EE=A*E*R