This presentation explains the eight pillars of Total Productive Maintenance ( TPM ) and TPM at Unilever.

1. 8 PILLARS OF TOTAL PRODUCTIVE
MAINTAINANCE ( TPM )
and
TPM AT UNILEVER
Group 5
Navaneeth R (P16199)
Nandan S Rajeev (P16198)
Bonny V Pappachan(P16179)
Bestin Syriac(P16178)
Chikku Biby Pittappilly(P16180)
Bavitha Babu(P16177)

3. About UNILEVER ..
 Consumer goods company
 Founded in 1930
 Headquartered in London
 Owns over 400 brands
 Divisions : Food , Refreshments , Home care & Personal care
 Products : 190 countries
 €52.7 billion turnover in 2016
 57% business is in emerging markets
 13 brands have sales of more than €1 billion a year
 169,000 people work for Unilever
 46% managers are women

4. Products

5. TPM at UNILEVER
 TPM : Total Productive Maintenance
 Improvement method
 Increases productivity

6. Introduction and first two
pillars of TPM
Submitted by NANDAN S RAJEEV

7. What is TPM?
 Total productive maintenance- Maintenance system which reduces down time.
 Low division between maintenance and normal workers.
 Just like Total quality management, in TPM everyone is responsible for machinery
used for production
 All machines should be in top condition.

8. Historical Perspective
 Nippodenso- A company which was a supplier of Toyota.

9. 5S Foundation
 Sorting-
 Setting in order-
 Shining- better visibility
 Standardisation-recorded logs
 Sustaining-scheduled maintenance

10. Pillar one- Autonomous maintenance
 Routine work done by crew freeing maintenance workers

11. Pillar two- Planned maintenance
 Schedules made on past observations and manufacturer replies.
 Reduces down time as planned maintenaces are primitive in nature.

12. Unilever and TPM
 Unilever follows WCM (World class manufacturing)
 WCM= Six Sigma+TPM+Lean
 Lean- Wastage

13. Pillar 3 & 4 : Focused Improvement
and quality maintenance
Submitted by,
BONNY V PAPPACHAN

14. Pillar III : OEE (Overall Equipment Efficiency)
Focused Improvement
Objectives
Maximizing the performance of equipment by minimizing losses
of equipment Problem Solving by GROUPS
Compare the ACTUAL operating time versus the OPTIMUM operating time
Highlight the causes of Productivity losses :
Availability, Performance and Quality losses
Improvement
Steps
Define
Losses
Quantify
Losses
Analyze
Causes
Generate
Counter-
measures
Implementation Follow
up

15. Pillar IV : Quality Maintenance
Aim
To ensure that a plant is in a perfect condition – where 100 % quality goods
are produced, zero defects
Ensuring high quality through equipment arrangements at
each process
Steps
Establish conditions for “zero defects”
Prevent the occurrence of quality defects
by maintaining the conditions within
certain standards
Inspect and monitor such conditions in
time series
Predicting the possibility of quality defect
occurrence by reviewing changes in
measured values
Take countermeasures in advance
Result Oriented Approach
“after it has happened”
Cause Oriented Approach
“before it happens”

16. Pillar 5 : Early Equipment Maintenance
 Uses the experience gathered from previous maintenance improvement activities
to ensure that new machinery reaches its optimal performance much early than
usual.
 The company is able to hit the ground running with highly reliable and productive
equipment.

17. It has a positive impact on profitability of the company .
Factors that should be considered when designing new equipment :
 Ease of cleaning and inspection
 Ease of lubrication
 Accessibility of equipment parts
 Improving operability of machines
 Feedback mechanisms
 Increased safety features

18. PILLAR 6 :EDUCATION & TRAINING
 Filling the knowledge gap that exists in an organization.
 Without proper training, tools such as TPM can be misunderstood by the staff.
 TPM education and training does not leave out any employee cadre.
 At lower level, operators’ skills are raised.
 At middle level, technical staff’s skills are improved.
 At higher level, helps managers to become competent mentors to their juniors.

19. Pillar 7: Health, Safety & Environment
 Workers must be able to perform their functions in a safe environment without
health risks.
 The health, safety and environment pillar of TPM ensures that all workers are
provided with an environment that is safe and that all conditions that are harmful
to their well-being are eliminated.
 When workers are in a safe environment, their attitude towards work changes.

20. Pillar 8 : TPM in Office Functions

21.  Easy for them to provide efficient service
 Spread of the principles to administrative functions within an organization
 Support functions understand the benefits of these improvements

22.  Removes the silo mentality and encourages horizontal cooperation within the
workforce
 Also be applied as stand-alone techniques