TPM

Prepared by :Duracell India Mfg.

Problem faced on shop floor

Frequent machine breakdown.
Poor speed and performance. High rate of wear and tear.

High operator attention required.

Poor quality at frequent intervals.

Large time wasted on petty things etc.

How to tackle it ?
Is there any solution ?

YES

Its TPM
Total Productive Maintenance

What is TPM ?
It s a new approach to equipment management. Equipment management is the set of activities that prevents quality defect and breakdowns, eliminates the need for frequent equipment adjustments and makes the work easier and safer

Aim of TPM

Zero Breakdown

Zero Defect Zero disaster

Important steps of TPM

Improvement activities to increase

equipment effectiveness. An autonomous maintenance program. A planned maintenance system.

How to improve equipment effectiveness ?

By elimination of six chronic losses

Breakdown losses.
Setup and adjustment losses. Idling and minor stoppage losses.

Speed losses
Quality defects and rework

Start up / yield losses.

Types of breakdown losses

Function loss break down
Function reduction breakdown

Function loss breakdown

They are very sudden and easy to notice . For example burning of a motor or breakage of shaft, tools etc.

Function reduction breakdown

It doesnt cause the stoppage of the machine but leads to reduced level of efficiency .For example jamming of the SWECO in powder making process.

Are there methods to prevent

breakdowns?

YES !

It can be reduced.

By following the six steps.

Steps for breakdown prevention

By eliminating accelerated deterioration. By maintaining basic equipment

conditions By maintaining operating conditions By improving maintenance quality Doing repair work beyond quick-fix measures. By learning as much as possible from each breakdown.

Preventing accelerated deterioration.

A milligram of prevention can save tons of cure. * Equipment overheats because of lack of oiling * Looseness in one part soon affects others, producing a chain reaction eventually leading to a breakdown

Basic equipment conditions.

HOW CAN IT BE MAINTAINED ?

By following the three steps.

Cleaning Lubricating Loose parts bolts etc tightening.

By maintaining operating conditions

Operating conditions like speed ,

feed , rpm, pressure etc should be displayed to avoid confusion and the parameters be strictly adhered .

By improving maintenance Quality

Can be improved by developing

the skill level through proper training and practice.

Finding a permanent solution.

Quick fix measures should be

avoided and efforts should be put to find the root cause so as to avoid the occurrence of the same problem time and again.

Learning from the break-down history

One should learn as much as possible from

each breakdown . Not only about the reasons or cause for breakdown but also about the various internal parts of the equipment. This will help in solving the same problem or a problem of similar type in much less time.

Set up and adjustment loss.

Losses occurring during machine setting

. For example setting height ,weight etc in the Stokes press of Depo room. It can be reduced by setting up a standard procedure for it and adhering to it.

Idling and minor stoppage losses

Caused by the temporary problem in the

equipment. For e.g ,

I

Work-piece jamming in the chute II Work-piece sensor not sensing leading to the shut down of the machine.

How to control idling and minor stoppage losses ?

By following these steps

Careful observation of what is happening. Correcting slight defects Understanding and following the optimal conditions.

Speed losses
Loss because of equipment

being run at low speed than it is designed for.

Causes for running at low speed

Mechanical problem like high vibration ,

sound etc. Defective quality. Fear abusing or overtaxing the equipment because of the ignorance about the actual speed.

Losses due to quality defects.

These are the losses because of improper

quality there by leading to either rework or rejection of the component and hence reducing the actual O.K output.

Ways to minimise quality losses.

Strictly adhering to the frequency of

checking as specified. Checking quality after any setting or alteration in the machine. Any chronic quality problem creator area to be taken up and solved.

Start up / yeild losses

It is the loss due to reduced yeild between

the time a machine is started up and when stable production is finally achieved . It is very difficult to identify. Operators keen observation required to reduce it.

Autonomous maintenance
Lets see what it is.

Traditional concept

I run it you fix it

Modern concept
The person who runs the machine is the best

person to take care of the equipment. Operators can easily prevent many breakdowns and quality problems by learning how to recognise abnormal conditions. This is what Autonomous maintenance says.

Three basic skills

Knowing how to distinguish between

normal and abnormal conditions . Knowing how to ensure that normal equipment conditions are met. Knowing how to respond quickly to abnormalities.

How do we implement Autonomous maintenance ?

A step-by-step approach to autonomous maintenance ?

Conducting initial cleaning. Eliminating sources of contamination and

inaccessible areas. Developing and testing provisional cleaning , inspection and lub. Standard. Conducting general inspection and developing inspection procedures. Doing general inspections autonomously. Organising and managing the workplace. Continuous improvements.

Initial cleaning
Cleaning is inspecting

So during cleaning one can look for dirt on chutes, foreign particle in sliding parts and also for other abnormalities which get exposed after cleaning.

Eliminate contamination sources

By controlling the sources of dirt.
By making cleaning and inspection easier

(By proper positioning of the parts)

Developing cleaning , Inspection and lubrication standards.

One has to decide as to which part of the

equipment needs cleaning and how often, which method to use , what to inspect while cleaning , how to judge whether conditions are normal and so on.

Key points for lubrication standard.

Clearly specify the lubricant to be used.
Clearly label all lubrication points Measure the lubrication consumption rate

and find out the frequency of filling. Review the disposal method for the used lubricant. Establish a service station.

Conducting general inspection and setting inspection procedures

You need to understand equipment

subsystems such as lubrication, equipment elements (tightening nuts and bolts) , pneumatics , hydraulics, electrical circuits , drive systems etc. Using this knowledge during inspection. For better inspection apply visual control as far as possible.

Visual controls for Lubrication

Colour coded marks to indicate oil inlets
Oil levels and supply interval levels Indication of upper and lower oil levels

Indication oil consumption per standard

time unit. Colour coding on oil cans to indicate oil type.

Visual controls for Equipment elements

Inspected marks and match marks
Colour coding on bolts(blue) reserved for

adjustment only during maintenance. Colour coding (yellow) on holes that do not require bolts.

Visual control for Pneumatics

Pneumatic pressure gage limits
Oil level display Display of upper and lower oil level limits

Labels on solenoids
Tube connection marks (Inlet,Outlet)

Colour coded supply lines

Flow direction arrows

Visual display for hydraulics

Hydraulic pressure gage
Oil level display Oil type display

Thermal level for hydraulic pump

Locknut match mark on relief valve

Visual controls for drive system

Indicate V-belt / Chain type.
Indicate V-belt /chain direction of rotation. Install peep window for checking belts.

Conducting inspection autonomously

Following review to be done before autonomous maint.

Review the item ,method and time standards

for cleaning inspection and lubrication. Finding out ways so that inspection tasks can be done within the scheduled work hours and making time saving improvements if necessary. Raising the inspection skill levels.

Loss structure during Production activities (16 major losses)

Operated man hour

Duty hour

Loaded man hour

Loading time

Net operational manhour

Effective man hour

Operating time
Non-operating time

Valued operating time