Find everything on production optimization and total productive maintenance in one set: definitions, illustrations and guidelines to improve your production plants. The TPM concept optimizes production processes and is of high significance when maintaining automated production plants. Total Productive Maintenance delegates different maintenance responsibilities to the production personnel to fill gaps between executives and staff. When you have the plan to put TPM measures into practice in your company, present basic ideas to your team and use the set as a guideline to achieve an optimization of your production plants. The set includes definitions and instructions to help you with any issue concerning Total Productive Management. http://www.presentationload.com/tpm-total-productive-maintenance-ppt-template.html

2. AGENDA 1. Quotes
2. What is Total Productive
Maintenance?
3. Why TPM?
4. Benefits of TPM
5. 8 Pillars of TPM
6. Implementation in 7 Steps
7. Key Figures of TPM
8. Objectives of TPM
9. Losses in the Production
Process
10. Implementation of TPM
11. Roles and Responsibilities
12. Sustainment of the TPM
Concept

3. DEFINITION
What is Total Productive Maintenance?
 Refers to all departments,
facilities and processes
 Participation of all employees
 Aim to eliminate all defects,
breakdowns,accidents etc.
 Maximization of the efficiency
of the production system
 Production of goods and
services that exceed the
customers’expectations
 Minimization of obstacles
within the production process
 Improvementof the efficiency
of facilities and plant
 Continuoussustainment
and improvementof the
overall condition of plant
and machinery
 Concerns whole life cycle
of the production system
TOTAL PRODUCTIVE MAINTENANCE

4. BENEFITS OF TPM
 Reduction of defects, interruptions
and waste
 Increase of productivity and running times
 Lower costs for maintenance and production
 Improved control of maintenance costs
 Less time for set-up and adjustment
of facilities
 Machines can be operated and maintained
more easily
 Improvement of standards for job safety
and process reliability
 Higher customer satisfaction
 Improved delivery results
DIRECT BENEFITS INDIRECT BENEFITS
 Increase of employee motivation
and satisfaction
 Varied and challenging work
 Sustainment of a clean, structured,
attractive work place
 Reaching goals in team work
 Exchange of knowledge and experience
 Higher qualification through education
and trainings
 Maintenance measures can be exercised
by the operator himself
 Employee feels responsible for avoiding
mistakes at “his” machine
 More participation and voice for employees

5. TYPES OF MAINTENANCE
Simple Approach
MAINTENANCE
PREVENTIVE CORRECTIVE
CALENDAR BASED CONDITION BASED PLANNED UNPLANNED

6. 8 PILLARS OF TPM
Design
Total Productive Maintenance
5S
QualityManagement
SafetyandHealthatWork,
EnvironmentProtection
ContinuousImprovement
PreventiveMaintenance
TrainingsandEducation
Start-upMonitoring
TPMinAdministration
AutonomousMaintenance

7. 8 PILLARS OF TPM
1. Continuous Improvement
 Applied elimination of major losses
2. Autonomous Maintenance
 Operator executes inspections, cleanings
and maintenance independently
3. Preventive Maintenance
 Undisturbed machines and facilities produce
faultless goods for total customer satisfaction
 Educated maintenance staff instructs machine operator
to improve the maintenance of their equipment
 Documentation of deficits with the help of scarcity cards
Continuous Improvement
Autonomous Maintenance
PreventiveMaintenance
Trainings and Education
Start-upMonitoring
Quality Management
TPM in Administration
Safetyand Healthat Work,
Environment Protection

8. IMPLEMENTATION OF PILLARS IN 7 STEPS
Initial cleaning of machines, equipment and surroundings
Elimination of problem sources and inaccessible areas
Draw up cleaning and lubrication standards
Conduction of general inspections
Conduction of autonomous inspections
Standards through visualization
Full autonomous maintenance
Step 4
Step 2
Step 3
Step 1
Step 5
Step 6
Step 7

9. QUALITATIVE OBJECTIVES
GOAL 6
Improvement of
cross-functional teamwork
GOAL 4
Optimization of
business performance
GOAL 3
Improvement of
corporate culture and image
GOAL 7
Increase of worker satisfaction
GOAL 8
Maximization of facility
efficiency
GOAL 2
Establish maintenance
throughout total equipment
life cycle
GOAL 5
Improvement of working environment
GOAL 1
Improvement of machine availability
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10. IMPLEMENTATION OF TPM
12 Steps Approach
PREPARATION
IMPLE-
MENTATION
START
STABILIZATION
6. Invitation of customers, affiliated companies and subcontractors
12. Raise TPM levels after perfect implementation
9. Development of an autonomous maintenance program
8. Development of a planned maintenance program
7. Development of an equipment management program
11. Development of equipment management program
10. Increase skills of production and maintenance staff
3. Promotion of TPM by special committees
2. Introductory education campaign for the workforce
1. Announcement to introduce TPM
5. Preparation and formulation of a master plan
4. Establishment of basic TPM policies and goals
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11. LOSSES IN PRODUCTION
6 Major Losses
OVERALL
EQUIPMENT
EFFECTIVENESS
AVAILABILITY
QUALITY
Breakdowns
Setups and
Adjustments
Reduced Speed
Stops and
Idle Times
Defects and
Rework
Startup and
Machine breakdowns over 10
minutes, > once a month
Times for set-up and
adjustment > 10 minutes
Suboptimal cycle times
and machine pulsing
Stoppages and idle times
over 10 minutes
Rework rate higher than 0,1%
Profit cuts by startup
difficulties
PERFORMANCE
1
2
3
4
5
6
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