TPM by Chandan Jha

WELCOME
TO THE WORLD OF

TPM
11

Prepared by : Chandan jha

TPM

2


ContentsContentsDefinition
History and origin,
List of TPM certified company.

Objective
Benefits of TPM
Why TPM,
TPM Goal
TPM Participants
TPM Strategies
Pillars of TPM
Op/Maint partnership
Autonomous maintenance
Slogans
Conclusion

3


Definition
“TPM is a management
process developed for
improving productivity
by making processes
more reliable and
less wasteful.”
4


HISTORY AND ORIGIN
FROM

TO

United States
Henry Ford
Preventive
Maintenance

Japan Nippon
Denso
Productive
Maintenance

5


HISTORY CONT’D…
Preventive maintenance along with Maintenance
prevention and Maintainability Improvement gave
birth to Productive maintenance.
By then Nippon Denso had made quality circles,
involving the employees participation. Thus all
employees took part in implementing Productive
maintenance.

6


HISTORY CONT’D…
TPM is a innovative Japanese concept which can be
traced back to 1951.
However the concept of preventive maintenance
was taken from USA. Nippondenso was the first
company to introduce plant wide preventive
maintenance in 1960.
Nippondenso which already followed preventive
maintenance also added Autonomous maintenance
done by production operators.
7


HISTORY CONT’D…
Whereas in most production settings the
operators are not viewed as a member of
the maintenance team, in TPM the
machine operators are trained to perform
many of the day-to-day tasks of simple
maintenance and fault-finding.
8


List of TPM certified

company.
Electrosteel Castings Limited
Exide Industries Limited
Indian Oil Corporation Limited
Jamshedpur Utilities and Services Company
Limited
MRF Limited
Munjal Showa Limited
National Engineering Industries Limited
Brakes India Ltd. Pad

9


List of TPM certified
CONT’D…
Brakes India Ltd. Foundry Div., Sholinghur
Galaxy Surfactants Ltd. Taloja and Tarapur
Hindustan Unilever Ltd. Khamgaon
Shriram Pistons & Rings Ltd.
Sundram Fasteners Ltd. Hosur
Sundram Fasteners Ltd. Pondicherry
Brakes India Ltd. Nanjangud
Hindustan Unilever Ltd.Haldia
10


OBJECTIVE
To restructure the corporate culture
through behavioral changes and
equipment improvements.

11


Similarities and differences

between TQM and TPM
Total commitment to the program by upper level
management is required in both programs
Employees must be empowered to initiate corrective
action.
A long range outlook must be accepted as TPM may take a
year or more to implement and is an on-going process
Changes in employee mind-set toward their job
responsibilities must take place as well.
12


WHY TPM?
Safe Work Environment
Job Security
Quality
Increased Productivity
Improved Skills

13


WHY TPM?CONT’D…
Avoid wastage in a quickly changing economic
environment.
Produce goods without reducing product
quality.
Reduce cost.
Produce a batch quantity at the earliest possible
time.
14


WHY TPM?CONT’D…
Creating company culture for maximum
efficiency.
Striving to prevent losses with minimum cost
The essence of team work (small group
activity) focused on condition and
performance of facilities to achieve zero loss.
Goods send to the customers must be non
defective.
15


GOAL OF TPM
Zero
Accide
nts

Zero
Product

Defect
s

Zero
Equipment
Failures

16


Team of TPM
TPM involves everyone in the
organization from operators to
senior management
In equipment
improvement. It
encompasses all
most all departments.

17


CONT’D…
The departments including:
Maintenance
Operations/production
Tool Room
Design Engineering
Project Engineering
Construction Engineering
Inventory and Stores
Purchase
Accounting and Finance 18
,etc

TPM STRATEGIES
Conduct more frequent and thorough
inspection and cleaning of machines to discover
minor discrepancies before they become
failures.
Enhance PMs to correct
minor defects and
prevent failures.
19


TPM STRAIT. CONT’D…
Modify Operations to reduce need for maintenance.
Elevate all employees’ knowledge, skill and role in
improving equipment performance.
– Engineers, Line Leaders, maintenance
technicians, and especially production operators.
20


TPM

Only clean machines and equipment
problems visually apparent!!!
Cleaning is Inspection.

CLEANING IS CHECKING !
21


The starting point for
TPM is implementing
routine inspections by
production operators.
“Autonomous maintenance” –Users/operators
perform continuous inspection for minor defects as
well as continuous cleaning, adjustment, and
tidying up the loosen parts.
22


Outline a detailed master deployment plan.
Improve the effectiveness of each piece of
equipment and concern person.
Develop an autonomous maintenance program
for operators.

23


Conduct training to improve operation and
maintenance skills.
Develop an early equipment management
program.
Continuous improvement.
Develop a planned for preventive
maintenance program.

24


PILLER OF TPM
Autonomous Maintenance
5-S
Jishu Hozen
Kaizen
Planned Maintenance
Quality Maintenance
Office TPM
Education & Training
Safety, Health & Environment
Development Management

25


Autonomous Maintenance
Activities where each
operator performs timely
inspection, lubrication,
consumable parts
replacement, repair,
troubleshooting, accuracy
checks, etc, of their own
equipment.

T P M

OIL

26


5-S
You can’t see problems clearly
when the workplace is in disarray
Cleaning and organizing the
workplace helps the team to uncover problems
Making problems visible
is the first step of improvement
Clean machines and
workplace create pride & Safety
TPM is the only tool to win the race, Keeping

5-S as its base.
27


JISHU HOZEN
PolicyUninterrupted operation of equipments.
Flexible operators to operate and maintain
other equipments.
Eliminating the defects at source through
active employee participation.
Stepwise implementation of JH activities.
JISHU HOZEN TargetsPrevent the occurrence of 1A/1B because of
JH.
Reduce oil consumption by 50%.
Reduce process time by 50%.
Increase use of JH by 50%.

28


JISHU HOZEN CONT’D…
Steps in JISHU HOZENPreparation of employees.
Initial cleanup of machines.
Take counter measures.
Fix tentative JH standards.
General inspection.
Autonomous inspection.
Standardization.
Autonomous management.
29


KAIZEN
Kai means change and Zen means good
The principle behind is a very large number of small
improvements are move effective in an organizational
environment than a few improvements of large value.

Policy
- Practice concepts of zero losses in every activity
- To achieve cost reduction targets in all resources
- To improve over all plant equipment effectiveness
- Focus of easy handling of operators

Target
- Achieve and sustain zero loses with respect to minor
stops, measurement and adjustments
- It also aims to achieve 30% manufacturing cost
reduction

30


PLANNED
MAINTENANACE
It is aimed to have trouble free machines and equipments
producing defect free products for total customer satisfaction.

Break down into 4 categories.
Preventive Maintenance
Breakdown Maintenance
Corrective Maintenance
Maintenance Prevention

Target
Zero equipment failure and break down.
Improve reliability and maintainability by 50%.
31


PM-CONT’D…
PMReduce maintenance cost by 20%
- Ensure availability of spares all the time
Six steps in planned maintenance
1. Equipment evaluation and recoding present
status
2. Restore deterioration and improve weakness
3. Building up information management
system
4. Prepare time based information system
5. Prepare predictive maintenance
6. Evaluation of planned maintenance

32


QUALITY MAINTENANCE
It is aimed towards customer delight through
highest quality through defect free manufacturing.
QM activity is to set equipment conditions that preclude
quality defects, based on the basic concept of maintaining
perfect equipment to maintain perfect quality of products.

Policy
o Defect free conditions and control of equipments
o QM activities to support quality assurance
o Focus of prevention of defects at source
o Focus on poka-yoka (full proof system)
33


QM-CONT’D…
QMIn-line detection and segregation of defects
- Effective implementation of operator
quality assurance

Target
- Achieve and sustain customer complaints
at zero
- Reduce in-process defects by 50%
- Reduce cost of quality by 50%

Quality defects are classified as customer
end defects and in house defects.

34


QM-CONT’D…
QMTarget
- Achieve and sustain downtime due to want men at
zero on critical machines.
- Achieve and sustain zero losses due to lack of
knowledge/skills/techniques.
- Aim at 100% participation in suggestion scheme.
Steps in education and training activities
- Setting policies and priorities and checking present
status of education and training
- Establish a training system for skill upgrading
- Preparation of training calendar
- Evaluation of activities and study of future approach
35


OFFICE TPM
Office TPM should be started after activating four other pillars
of TPM (JH,KK,QM,PM).

Office TPM addresses 12 major losses
- Processing loss
- Cost loss in areas like accounts, marketing and sales
- Communication loss
- Idle loss
- Set-up loss
- Accuracy loss
- Office equipment breakdown, telephones and fax
- Communication channel breakdown
- Time spent on retrieval of information
- Non availability of correct on line stock status
36


OFFICE TPM
CONT’D…
Customer complaints due to logistics
- Expenses on emergency dispatches/purchases

Benefits
- Involvement of all people in support functions for
focusing on better plant performance.
- Better utilized work area
- Reduce repetitive work
- Reduce administrative costs
- Reduction in number of files
- Reduction in office equipment
- Reduce customer complaints
- Reduce manpower
- Clean and pleasant work environment

37


Education & Training
It is aimed to have multi skilled employees whose morale is
high and who has eager to come to work and perform all
required functions effectively and independently.

They are trained to achieve 4 phases of skills
Phase 1 : Do not know
Phase 2 : Know the theory but cannot do
Phase 3 : Can do but cannot teach
Phase 4 : Can do and also teach

Policy
- Focus on improvement of knowledge and skills
- Create a training environment for self learning
- Training to remove employee fatigue and make
work enjoyable

38


SAFETY,HEALTH AND
ENVIRONMENT
Target
- Zero accident
- Zero Health damage
- Zero fires
It helps to create a safe workplace and a surrounding area that
is not damaged by our process or procedures.
It plays an active role in each of the other pillars on a regular
basis.
To create awareness among employees various competitions
like safety slogans ,posters etc can be organized at regular
intervals.

39


OMP - OPERATOR
MAINTENANCE PARTNERSHIP
Operator training in TPM
Operator basic equip
inspection & tooling checks
Operator basic cleaning
Operator lubrication check
One point lessons (capture
knowledge)

TPM

40


CONT’D…
The Ethics of
operator is to
operate the
equipment with
high skills level,
in order to
reduce the down
time.

The Ethics
of
Maintenanc
e team is to
upgrade the
equipment
to perform it
better.
41


CONT’D…
Operator and
Equipment

Mother and
baby

42


SEE THE BELOW
IMAGES…..

43


WHAT WAS

COMMON
IN ABOVE IMAGES ?

48


LACK OF KNOWLEDGE ?

49


LACK OF AWARENESS ?

50


LACK OF TRAINING?

51


THE ANSWER IS :
“LACK OF OWNERSHIP”
THAT IS ATTITUDE PROBLEM.

52


ATTITUDE /

THOUGHT
53


THOUGHT CHANGE
Old concept

New concept

I operate the
machine and
some body
maintains it.

I operate the
machine and
I maintain
it.
54


SEE THE BELOW IMAGES…..

55


What was common
in above pictures

60


THE ANSWER IS…

61


WHAT IS THE GOAL OF OPERATOR
AUTONOMOUS MAINTENANCE?
“Keeping one's
own equipment
in good
condition by
oneself ”.
62


SLOGANS
TPM In, Losses Out.
Machine not tight, job not right.
Organization without TPM; Building without
foundation.
Farmer is the backbone of a country; TPM is
the backbone of industry.
Accept TPM with a Positive Attitude
Achieve Success of high Magnitude.
63


SLOGANS
TPM is the foundation of factory.
Invest minutes for TPM; Gain hours for
production.
Your future is bright, when the TPM
you practice is right.
Don’t be a fool, use TPM tool.
64


AT LAST
“TPM is a Lean
tool for Quality and
Productivity”
65


CONSLUSION
Today, with competition in industry is high.
TPM may be the only tools that stands us
success. It has been proven to be a program
that works.
Employees must be educated and convinced
that TPM is not just another "program of
the month" .
If everyone involved in a TPM program, an
unusually high rate of return compared to
resources invested may be expected.

66


I sincerely thank you for your co-operation and
consideration for the growth of TPM.

THANK YOU,

Presented by:

CHANDAN JHA

67

chandanjha16@yahoo.co.in

TPM by Chandan Jha

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