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What is TPM?
 
 


©TPM is a plant improvement

methodology which enables
continuous and rapid improvement
through use of employee
involvement, employee
empowerment, and closed-loop
measurement of results.µ
 m complete definition of TPM includes
the following five elements:
1. TPM aims to maximize equipment
effectiveness.
2. TPM establishes a thorough system of PM
for the equipment·s entire life span.
3. TPM is implemented by various
departments (engineering, operations,
maintenance etc).
4. TPM involves every single employee, from
top management to workers on the floor.
5. TPM is based on the promotion of PM
through motivation management:
autonomous small group activities.
  


  

 


 

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 ptimum relationships between
people and equipment/process
 Involvement of everyone, from top
leadership to shop floor workers
 m cross-functional approach,
involving all departments
 Implementation through small group
teamwork



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 verall Equipment Effectiveness

(EE) Improved
 Mean Time Between Failure
Improved
 Mean Time To Repair Improved
Types of Maintenance

 ©Means the act of maintaining, 




 That is, to keep in due (rightful,
proper, fitting) condition, operation,
or force; keep unimpaired.
 Types of Maintenance
 1. Breakdown maintenance: It means
that people waits until equipment fails
and repair it.
 2. Preventive maintenance: It is a
daily maintenance design to retain the
healthy condition of equipment and
prevent failure
2a. Periodic maintenance (Time based
maintenance - TBM) :
2b. Predictive maintenance
Types of Maintenance
 3. Corrective maintenance (1957) :
It improves equipment and its
components so that preventive
maintenance can be carried out
reliably.
 4. Maintenance prevention (1960):
It indicates the design of new
equipment.
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Pillars of TPM
 Pillar-- 1 5S
Pillar
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: Separate out all that is unnecessary and eliminate it.

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: Put essential things in order so they can be easily
accessed. Everything has a place« and is in its place. mnd
visual management.


: Clean everything ² tools and workplaces ² removing

stains, spots, debris and eradicating sources of dirt.
Bring everything to ©EWµ and better than new.



(: Standardize the previous three steps to
make the process one that never ends and can be
improved upon.



: Make cleaning and checking routine.
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The 7 steps of mutonomous

mutonomous
Maintenance
1. Initial Cleaning (Initial Inspection &
´Resto ationµ)

2. Sou ce of Contamination & Ha d-

Ha d-to-
to-
Reach a eas

3. Standa ds of Cleaning & Lub ication

4. Gene al Inspection

5. mutonomous Inspection

6. Standa dize mutonomous Maintenance

ope ations

7. mutonomous Management
 nomous Maintenance
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*Compare the mCTUmL operating time versus the

PTIMUM operating time

*Highlight the causes of Productivity losses :

mvailability,, Performance and Quality losses
* mvailability
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 Practice concepts of zero losses in
every sphere of activity.
 relentless pursuit to achieve cost
reduction targets in all resources
 Relentless pursuit to improve over all
plant equipment effectiveness.
 Extensive use of PM analysis as a tool
for eliminating losses.
 Focus of easy handling of operators
 PILLmR
PILLmR--3- EE

Improvement Steps

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Planned Maintenance-
Maintenance- Policy

 mchieve and sustain availability of

machines
 ptimum maintenance cost.
 Reduces spares inventory.
 Improve reliability and
maintainability of machines.
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To ensure that a plant is in a
perfect condition ² where 100 %
quality goods are produced, zero
defects
Result riented
mpproach
´after it has happenedµ

Cause riented mpproach

´efore it happensµ
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bjectives
1) Enhance employees· ability and
skill in TPM methods
2) Provide necessary TPM
methodology at the right time
3) Provide challenge targets for
individuals by clarifying the
hierarchy of skills
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 Step 1: Skills/Techniques Inventory and
Hierarchy
âCreate a list of perational and Maintenance
Skills and Techniques
 Step 2: Design Training System
âIncluding follow-up system such as T (on
the job training)
âDocumentation of Individual Skill Levels
 Step 3: Set Individual Skill Challenge Target
 Step 4: Training and Evaluation
Pillar VII : mdministrative
Work Improvement

Oetives
1 inimie losses
 Improve 
alit o work
3 Clear work alloation
Pillar VII : mdministrative
Work Improvement
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 Today, with competition in industry at an
all time high, TPM may be the only thing
that stands between success and total
failure for some companies. It has been
proven to be a program that works. It can
be adapted to work not only in industrial
plants, but in construction, building
maintenance, transportation, and in a
variety of other situations. Employees
must be educated and convinced that TPM
is not just another "program of the month"
and that management is totally committed
to the program and the extended time
frame necessary for full implementation