includes introduction goals types benefits pillars of TPM and finally 5s principles of TQM

1. TOTAL PRODUCTIVE
MAINTENANCE & 5S
BY:
ARUN JOSE
SANDEEP kumar s
Thilak r
Mba bangalore

2. GOAL
1.To Increase production while, at the same
time, increasing employee morale and job
satisfaction.
2. Hold emergency & unscheduled maintenance
To a minimum.

3. Why we need TPM ?
The major objectives of the TPM are listed as under :
 Avoid wastage in quickly changing environment.
 Reduce Cost of Manufacturing.
 Produce a low batch quantity at the earliest possible time.
 Goods send to Customers must be “ non – defective”

4. TYPES OF MAINTENANCE
1. Breakdown Maintenance
2. Preventive Maintenance
a). Periodic Maintenance
b). Predictive Maintenance
3. Corrective Maintenance
4. Maintenance Prevention

5. TPM TARGETS
1. PRODUCTION
I). Obtain Minimum 80% Overall Production Efficiency
ii). Obtain Minimum 90% Overall Equipment Effectiveness
iii). Run the Machine during lunchtime
2. QUALITY
Operate in a manner, so that there are no customer complaint.
3. COST
Reduce the manufacturing cost by ----- Per Cent
4. DELIVERY
Achieve 100% success in delivering the goods as required by the
customer

6. 5. SAFETY
Maintain an accident free environment
6. MULTYTASK
Develop multiskilled & flexible workers.

7. Motives of TPM
 Adoption of Life – Cycle approach for improving the overall performance of
production equipment's.
 Improving Productivity by highly motivated workers which is achieved by Job –
Enlargement.
 Formation of team of volunteers for activities which cause of failure, possible
reduction of cycle time; and equipment / process modifications.
Uniqueness of TPM
 The major difference between TPM and other concepts is that the operators are
also made to involve in the maintenance process.

8. Direct Benefits of TPM
 Increase Productivity and Overall Plant Efficiency by 1.5 to 2 times
 Rectify customers complaints
 Reduce manufacturing cost by ….percent
 Satisfy the customers needs by 100%
 Reduce accidents
 Comply with all relevant governmental regulations

9. Indirect Benefits of TPM
 Higher confidence level among the workers
 Keep the work place clean, neat and attractive
 Favorable change in the attitude of the operators
 Achieve goals by working as Team
 Share knowledge and experience
 The worker get a feeling of OWNING the machine

10. Introducing TPM at a Production Unit
STEP – 1. Preparatory Stage
 Announcement by TOP MANAGEMENT to all about
TPM introduction in the organization
 Initial education and publicity for TPM
 Setting up TPM & Departmental committees
 Establishing the TPM working systems & target
 A master plan for institutionalizing

11. STEP – 2. Introduction Stage
STEP – 3. Implementation
STEP – 4. Institutionalizing Stage

12. TOP
MANAGEMENT
TPM
OFFICE TPM Responsible
Plant Manager
5 S
Autonomus
Maintenance
Planned
Maintenance
Individual
Improvement
Quality
Maintenance
Early Equipment
Management
Safety
Tra ni ing &
Development

14. 5S PRINCIPLES OF TQM

15. S.NO JAPANEES ENGLISH
1S Seiri (Sort)
2S Seiton (Straighten)
3S Seiso (Shine)
4S Seiketsu (Standardize)
5S Shitsuke (Sustain)

17. ,

20. 2S
STRAIGHTEN
 Organizing
 Arrange items so that they
are easy to find and easy to use.
 “A place for everything, and
everything in its place”

21. 3S
SHINE
 Cleaning must be done on regular basis
 Initial “deep cleaning” may be necessary
 Challenge is to then implement regular housekeeping so that any
dirt or grease is Immediately obvious.

22. Shine Targets
 Storage Areas Warehouses , shelves & tool storage, etc…
 Equipment Machinery , handling lifts etc….
 Surroundings Windows , Meeting rooms , top of cabins,etc….

23. 4S
Standardize
 Set in order and Shine are properly maintained.
Audit the workplace for progress on:
a) Clearing up: Elimination of unnecessary items.
b) Organizing: Needed items in designated places.
c) Cleaning :Everything should be clean that any dirt is noticed
immediately.

24. 5S
SUSTAIN
 Means making a habit of properly maintaining correct procedures.
 This step is to ensure that create general awareness about 4S
 Training to everyone.
 Develop norms and monitor success.
 Involvement of people in the movement.

26. THANK YOU