Introduction to Total Productive Maintenance (TPM)
Introduction to Total Productive Maintenance (TPM)
Presented by: SIKANDAR ALI
Under the guidance: MAHMOOD ALAM SIR
Department of Mechanical Engineering
Integral University, Lucknow. 1
Why TPM need
Pillars of TPM
Benefits of TPM
List of TPM Certified Company
is a unique Japanese philosophy.
concept was first introduced by M/s Nippon Denso Co. Ltd
Productive Maintenance is a maintenance program
which involves a concept for maintaining plants and
Involvement of all people from top management to operator.
is the goal of the TPM program to increase production,
employee motivation, and job satisfaction by eliminating
emergency repairs and unscheduled maintenance break
Participation of all Employees.
Include all Departments, operation,
Pursue the maximization of efficiency of the production
by making all loses zero.
Zero accidents Zero defects Zero breakdowns.
To improve the efficiency of the equipment.
Maintenance means the entire life cycle of the production
It is a Japanese approach for
Creating company culture for maximum efficiency.
Striving to prevent losses with minimum cost
Zero breakdowns and failures, Zero accident,
and Zero defects etc.
Involvement of all people from top management to
Reduce Cost of Manufacturing
Goods send to Customers must be “ non –
of TPM can be traced back to 1951.
was the first company to introduce plant wide
preventive maintenance in 1960.
first introduced in 1971, Nippon Denso Co., Ltd
first example of TPM used in Europe to deliver world
class performance was by Volvo in Ghent, Belgium.
wastage in a quickly changing economic
Producing goods without reducing product quality.
Goods send to the customers must be non defective.
Safe Work Environment
Increase production while, at the same time, increasing
employee morale and job satisfaction.
Hold emergency & unscheduled maintenance to a
To provide the safe and good working environment to the
Achieve Zero Defects, Zero Breakdown and Zero accidents
in all functional areas of the organization.
Involve people in all levels of organization.
I). Overall Production Efficiency.
ii). Overall Equipment Effectiveness.
Operate in a manner, so that there are no customer complaint.
Reduce the manufacturing cost as much as possible.
Achieve 100% success in delivering the goods as required by the
Maintain an accident free environment.
Develop multiskilled & flexible workers.
1 - Autonomous Maintenance
Team activity involving production, maintenance, and engineering.
Maintaining Basic conditions on shop floor & in Machines.
Develops operating and maintenance skills.
Prevent equipment deterioration through correct operation and daily
Bring equipment to its ideal state through restoration and proper
Establish the basic conditions needed to keep equipment well
2 - Focused Improvement
Improvement on every one’s activity.
Improvement is to eliminate Production losses and cost reduction.
Improvement in Reliability, Maintainability, and cost.
PILLAR 3 - Planned Maintenance
• Logical analysis “Real causes for real counter measures”.
• Focus on Prevention.
• It is aimed to have trouble free machines and equipments
producing defect free products for total customer satisfaction.
PILLAR 4 - Quality Maintenance
• Developing perfect machine for perfect Quality.
• Eliminating In – Process defects and custom complaints.
• Defect free conditions and control of equipments.
• QM activities to support quality assurance.
• Focus of prevention of defects at source
• Effective implementation of operator quality assurance
PILLAR 5 - Education & Training
• Skills development for uniformity of work practices on machines.
• Skills for Zero defects, Zero breakdowns & Zero accidents.
• Multi Skilled employees in all departments
The employees should be trained on the basis of his knowledge:
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.
PILLAR 6 - Development Management
KAI means change and ZEN means good (for the better).
Basically Kaizen is for small improvements, but carried out on
a continual basis and involves all people in the organization.
Kaizen Policy :
• Achieve cost reduction targets in all resources.
• Improve over all plant equipment effectiveness.
• Focus of easy handling of operator
PILLAR 7 - Safety, Health & Environment
Zero accidents and Zero hazards at works.
Zero Pollution at Plant and Environment
PILLAR 8 - Office TPM
Office TPM must be flowed to improve productivity, efficiency in
the administrative function and identify eliminate losses.
This includes analyzing process and procedure towards increased
office automation. Office TPM covers these major losses:
Cost loss, accounts marketing leading to high inventories.
Office equipment breakdown.
Communication channel breakdown.
Direct Benefits of TPM
and Overall Plant
Efficiency by 1.5 to 2
cost by ….percent.
Satisfy the customers
needs by 100%
Indirect Benefits of TPM
Higher confidence level
among the workers.
Keep the work place
clean, neat and
Favorable change in the
attitude of the operators.
Achieve goals by working
Share knowledge and
LIST OF TPM CERTIFIED COMPANY
Indian Oil Corporation Limited.
Hindustan Unilever Ltd. Khamgaon
Hindustan Unilever Ltd. Haldia
Brakes India Ltd. Nanjangud
Brakes India Ltd. Pad
Brakes India Ltd. Foundry Div., Sholinghur
Shriram Pistons & Rings Ltd.
Exide Industries Limited.
Jamshedpur Utilities and Services Company Limited.
Munjal Showa Limited.
Galaxy Surfactants Ltd. Taloja and Tarapur
Sundram Fasteners Ltd. Hosur
Sundram Fasteners Ltd. Pondicherry
TPM is a Lean tool for Quality and Productivity
Today, with competition in industry at an all time high, TPM may be the only
thing that stands between success. If everyone involved in a TPM program
does his or her part, an unusually high rate of return compared to resources
invested may be expected.
• It can be adapted to work not only in industrial plants, but in
construction, building maintenance, transportation, and in a variety of
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I sincerely thank you for your co-operation and consideration .
Presented by: SIKANDAR ALI