This document provides an overview of Total Productive Maintenance (TPM). TPM is a holistic approach to equipment maintenance that aims for perfect production with no breakdowns, small stops, defects, or accidents. It involves 8 principles: autonomous maintenance by operators, planned maintenance based on failure rates, quality maintenance to eliminate defects, focused improvement through cross-functional teams, early equipment management to improve new designs, training and education, maintaining safety and health, and applying TPM techniques to administrative functions. The goals are to maximize equipment efficiency through proactive maintenance and empowering operators while reducing waste.

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BASIC AWARENANCE TRAINING ON
TPM
(TOTAL PRODUCTIVE
MAINTENANCE)
TPM

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What is Meaning of Waste ?
"waste" is everything that no longer has a use or purpose
and needs to be disposed of, right? Right. The term
certainly applies to discarded material, but there are
specific definitions for waste that affect how waste is
regulated and must be handled, especially in professional
settings.
TPM

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How to Eliminate Waste….
Making a great number of continuous lasting
improvements
• Discovering small problems and eliminating them.
• Attacking causes of problems, not just the symptoms.
• Total Productive maintenance leads to improving
activities as against processes related to machine.
•Whatever we do can be continuously improved, be it our
working life or personal life.
TPM

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Basic Points For Watching the Work site
1. Look into the Rejection area – Watch the work site and
look for causes of defects.
2. Watch the worker’s movements & displacements – Isn’t
there any wasted movements?
3. Watch the work flow – Isn’t there any part accumulation in
the process or line ?
4. Watch scrap – Isn’t there any room for reuse or
recirculation ?
5. Watch rubbish – No usable material ?
6. Watch stopped machines – Isn’t there any wasteful
operation, conveyer moving or engine running?
TPM

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Types of Wastes
EACH EMPLOYEE SHOULD KNOW ABOUT – MUDA ( WASTES)
- MURI (STRAIN)
- MURA (DISCREPANCY)
THE SEVEN WASTES
1. Overproduction
2. Delays (waiting time)
3. Transportation
4. Excessive Process
5. Inventories (Stocks)
6. Motions (Movements)
7. Making Defective products
TPM

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Elimination of Waste
Identify
waste
Search for
causes
Implement
continuous
improvement
The Method
Check and
measure
results

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Elimination of Wastes and Continuous Improvement
Elimination of
wastes
KAIZEN
Continuous
Improvement
One piece flow
SMED
Visual Controls
Workplace
Organization
Kanban
Standard Work
Process Control
Total Productive
Maintenance
Poka-Yoke
•Lead-time
•Costs
Quality
the
First Time
The Approach The Means The Strategy

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Total Productive maintenance (TPM) is
the one of the tool for Continuous
Improvement
& elimination of waste

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What is the Meaning of TPM ?
TPM (Total Productive Maintenance) is a holistic
approach to equipment maintenance that strives to
achieve perfect production
 No Breakdowns
 No Small Stops or Slow Running
 No Defects
 No Accidents

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TPM - History:
 TPM is a innovative Japanese concept which can be
traced back to 1951.
 However the concept of preventive maintenance was
taken from USA. Nippon denso was the first company to
introduce plant wide preventive maintenance in 1960.
 Nippon denso which already followed preventive
maintenance also added Autonomous maintenance done
by production operators.

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What is the Purpose of TPM ?
 TPM emphasizes proactive and preventative maintenance to
maximize the operational efficiency of equipment.
 It blurs the distinction between the roles of production and
maintenance by placing a strong emphasis on empowering
operators to help maintain their equipment.
 The implementation of a TPM program creates a shared
responsibility for equipment that encourages greater involvement
by plant floor workers.
 In the right environment this can be very effective in improving
productivity (increasing up time, reducing cycle times, and
eliminating defects).

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TPM - 8 principles
1.Autonomous Maintenance.
2.Planned Maintenance
3.Quality Maintenance
4.Focused Improvement
5.Early Equipment
6.Training and Education
7.Safety,Health Environments
8.TPM in Administration

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TPM - 8 principles

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Places responsibility for routine maintenance, such as cleaning,
lubricating, and inspection, in the hands of operators.
• Gives operators greater “ownership” of
their equipment.
• Increases operators’ knowledge of their
equipment.
• Ensures equipment is well-cleaned and
lubricated.
• Identifies emergent issues before they
become failures.
• Frees maintenance personnel for
higher-level tasks.
Autonomous Maintenance helps :
1.Autonomous Maintenance

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1.Autonomous Maintenance –
My Machine Concept
• Routine Inspection
• Oiling
• Leakages (oil & air)
• Oil & Coolant Levels
• Abnormal Noises
• Machine cleaning
• Quality of the product
• OEE
I AM RESPONSIBLE FOR:
Operator Name &
Employee ID
Operator Photo

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2.Planned Maintenance
Schedules maintenance tasks based
on predicted and/or measured failure
rates.
 Significantly reduces instances of
unplanned stop time.
 Enables most maintenance to be
planned for times when equipment
is not scheduled for production.
 Reduces inventory through better
control of wear-prone and failure-
prone parts.
Planned Maintenance helps :

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3.Quality Maintenance
Design error detection
and prevention into
production processes.
Apply Root Cause
Analysis to eliminate
recurring sources of
quality defects.

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3.Quality Maintenance
 Specifically targets quality issues
with improvement projects
focused on removing root sources
of defects.
 Reduces number of defects.
 Reduces cost by catching defects
early (it is expensive and
unreliable to find defects through
inspection).
Quality Maintenance helps :

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4. Focused Improvement
Have small groups of employees work together
proactively to achieve regular, incremental
improvements in equipment operation.

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4. Focused Improvement
Focused Improvement helps :
 Recurring problems are identified and resolved by cross-
functional teams.
 Combines the collective talents of a company to create an
engine for continuous improvement.

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5. Early Equipment Management
Directs practical knowledge and understanding of manufacturing
equipment gained through TPM towards improving the design of
new equipment.

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5. Early Equipment Management
Early Equipment Management helps :
 New equipment reaches
planned performance
levels much faster due to
fewer startup issues.
 Maintenance is simpler
and more robust due to
practical review and
employee involvement
prior to installation.

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6. Training and Education
Fill in knowledge gaps necessary to achieve TPM goals.
Applies to operators, maintenance personnel and managers.

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6. Training and Education
Training and Education helps :
• Operators develop skills to
routinely maintain equipment
and identify emerging
problems.
• Maintenance personnel learn
techniques for proactive and
preventative maintenance.
• Managers are trained on TPM
principles as well as on
employee coaching and
development.

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7. Safety, Health, Environment
Maintain a safe and healthy working environment.

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7. Safety, Health, Environment
Safety,Health,Environment helps :
 Eliminates potential
health and safety
risks, resulting in a
safer workplace.
 Specifically targets
the goal of an
accident-free
workplace.

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8. TPM in Administration
Apply TPM techniques to administrative functions.
 Extends TPM benefits beyond the plant floor by addressing
waste in administrative functions.
 Supports production through improved administrative
operations (e.g. order processing, procurement, and
scheduling).
TPM in Administration helps :

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8. TPM in Administration
Example:

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