TPM Introduction

Presentation Structure

TPM definition
A Company-wide team-based effort to build quality into
equipment and to improve overall equipment
effectiveness

Total
all employees are involved
it aims to eliminate all accidents, defects and
breakdowns

Productive
actions are performed while production goes on
troubles for production are minimized

Maintenance
keep in good condition
repair, clean, lubricate

Evolution of TPM

TPM began by studying American Preventive

Maintenance techniques.

Seiichi Nakajima developed TPM based on observations

of American practices and adapted to Japanese
environment in 1971.

Over the period of years since 1971 the scope of TPM

includes all the departments in an organisation and not
just manufacturing.

Started with Automobile industriesmoved to assembly

line & Semiconductor indst.

1980s onwards found its way to process industries

including chemicalsfoodstuffs cement etc.

TPMs Origin at Nippondenso

A member

of Toyota Group.

Manufacturer
spares.
Introduced
1961.

of general automobile
Productive Maintenance in

Launched it as Total-Member-participation
PM

in -1969.

Received

PM awardfor 1971.

Promoted

and spread by JIPE / JIPM

What is TPM ?

TPM aims to create a system that maximizes the

overall efficiency of the production system
TPM creates systems for preventing the occurrence of all
losses . This includes systems for realizing Zero
accidents , Zero defects and zero failures in the entire
life cycle of the production system
TPM is applied in all functions - production ,
development , supply chain , HR etc
TPM is based on participation of all members - top
management to front line employees
TPM achieved zero losses thru overlapping small
group activities

Total Productive Maintenance

The principle characteristics of a TPM system:

1. Operators perform Preventive Maintenance functions they have
been trained to perform , that do not require the capabilities of
a skilled tradesman.
2. Skilled maintenance personnel train the operators and develop
one-point lessons.
3. Maintenance department moves from a fire-fighting mode to
a prevention mode & re-engineering.

TPM: Goals & Objectives

1. To get the most efficient use of all production equipment
(i.e. overall equipment effectiveness or APU).
2. To establish a total (company wide) PM system, encompassing
Predictive Maintenance, Preventive Maintenance
and Improvement related Maintenance.
3. To achieve full participation of equipment designers and engineers,
equipment operators, and maintenance department personnel.
4. To effectively involve every employee in the Company from the shop floor
associate to all aspects of upper management.
5. To promote and implement PM related autonomous, small-group
activities targeted at continuous improvement of operating efficiency.

TPM: Performance
Objective of production improvement activities is
to increase productivity by minimizing input and
maximizing output
Output includes apart from Quantity

Improving quality

Reducing costs

Meeting delivery schedules

conditions
and work environment
Increasing morale and

Increasing safety health

P
Q
C
D
M
S

Training

Foundation pillar of TPM 5'S'

Office TPM

Health Safety and Environment

Quality Maintenance

Focused Improvement (Kbetsu Kaizen)

Planned Maintenance

Autonomous Maintenance (Jishu Hozen)

TPM: Structure

TPM:

Autonomous Maintenance (JH)

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 deterioration before
it affects the process or leads to a failure

TPM:

Autonomous Maintenance (JH)

7 steps are implemented to progressively increase operators

knowledge, participation and responsibility for their equipment
1. Perform initial cleaning and inspection
2. Countermeasures for the causes and effects of dirt and dust
3. Establish cleaning and lubrication standards
4. Conduct general inspection training
5. Carry out equipment inspection checks
6. Workplace management and control
7. Continuous improvement

TPM: Focused Improvement (KK)

Objective: maximize efficiency by eliminating waste

and manufacturing losses
Manufacturing losses are categorized into 13 big
losses:
Equipment losses (6)
Manpower losses (4)
Material losses (3)

TPM: Focused Improvement (KK)

- Equipment losses

Downtime
loss

Equipment failure / breakdowns

Set-up / adjustments

Minor stopping / idling

Speed loss
Reduced speed

Process errors
Quality loss
Rework / scrap

TPM: Focused Improvement (KK)

- Manpower and material losses
Cleaning and checking
Manpower
losses

Waiting materials
Waiting instructions
Waiting quality confirmation

Material yield
Material
losses

Energy losses
Consumable material losses

TPM: Focused Improvement (KK)

- Overall Equipment Effectiveness (OEE)

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 planned loading
time. Planned downtime does not effect the OEE figure.
Overall Equipment Effectiveness = Availability x Performance x Quality Yield

Availability

Down Time Loss

Performance

Quality Yield

Speed Loss

Quality Loss

TPM: Focused Improvement (KK)

- Overall Equipment Effectiveness (OEE)

Overall Equipment Effectiveness = Availability x Performance x Quality Yield

Availability = time available for production - downtime

time available for production
Performance = ideal cycle time x number of parts produced
operating time
Quality Yield = total number of parts produced - defect number
total number of parts produced

TPM:

Planned maintenance

Objective: establish Preventative and Predictive

Maintenance systems for equipment and tooling

Correct operation

Correct set-up

Cleaning

Lubrication

Retightening

Feedback and repair of minor defects

Quality spare parts

TPM:

Quality Maintenance

Definition: a process for controlling the condition of

equipment components that affect variability in product quality

Objective: It is aimed towards customers delight through

highest quality through defect free manufacturing.

Achieve and sustain customer complaints zero

Reduce in process defect
Reduce cost of quality

TPM:

Office TPM

Administrative and support departments can be seen as

process plants whose principal tasks are to collect,
process, and distribute information
Process analysis should be applied to streamline
information flow

TPM:

Health, Safety and Environment

Objective: Assuring safety and preventing adverse

environmental impacts are important priorities in any TPM
effort

Target:
Zero Accident
Zero health damage
Zero Fire

TPM:

Foundation Pillar

Foundations of TPM
5S
Seiri

Clearing

Organising

Seiso

Cleaning

Seiketsu

Standardising

Shitsuke

Discipline

1S

2S

Seiton

3S

4S
5S

A 5S Desk

Record Room

A 5S Stationary Box

Records Storage

r
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f
Be
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Thanks