Total Productive Maintenance

SARA Infotech (P) Ltd.

Bombay, India.

Aims of TPM

        To maximize the production system To organize a practical shop-floor system Zero accidents Zero defects Zero breakdown To involve all the functions of an organization To involve every employee To achieve Zero loss

The Pillars of TPM

        Focused improvement Autonomous maintenance Plant- Maintenance Office Maintenance Product Design and Equipment Initial Control Quality Maintenance Worker’s Education & Training Safety, Hygiene & Environment Control.

TPM Goals

 Achieve zero breakdowns & zero losses thru - Focused Improvement, - Effective Equipment Management Techniques - Autonomous Maintenance Systems.

Cont.

TPM Goals

 Prevent losses before they occur thru - Integrated functions of production - Maintenance - Technical - Commercial - Administration - Finance - Marketing.

Cont.

TPM Goals

 Achieving zero defects, to - become a consistent supplier of quality products and services - conform customer specifications.

Cont.

TPM Goals

 Give effective training to develop highly skilled, motivated and self-reliant workforce.

 Prolong life span of equipment by maintainability improvement.

Cont.

TPM Goals

 Involve all the members of the team to develop an atmosphere that is congenial friendly energetic which is resulting in pride of job performed with a feeling of ownership of the asset.

Cont.

TPM Goals

 TPM ensures environment that is Clean Accident free Pollution free a working Cont.

TPM Organization

 TPM promotion committees: Company TPM Promotion Committee Plant Promotion Committee Subcommittee of Kaizen Sub-committee of Autonomous Maintenance Sub-committee of planned maintenance Sub-committee of initial flow control Sub-committee of Quality Maintenance Sub Committee of office improvement Education and training committee Safety and Hygiene Committee

Role of TPM Promotion Committee

- Basic policy and Target Setting the Audit of the promotion progress and education and cultivation of Implementation plan.

- Approval of implementation plan Workout remedial measures against problems encountered during promotion of the activities.

- Organize the project teams.

Role of the Plant Promotion Committee

- Workout the plan to promote Jishu Hozen and and check the promotion activities.

Kobetsu-Kaizen progress of Review problems and instructions to small groups give - Organize Kobetsu-Kaizen project teams.

Role of the Subcommittee of Kaizen

Instruct on how to practice “Kobetsu-Kaizen” Instruct on how to horizontally replicate TPM.

Analysis of improvement activities – Quantitative and Qualitative Standardization and information exchange.

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Role of the Company TPM Promotion Committee

Study how to proceed with the autonomous maintenance step by step Development.

- To conduct Audit after completion of each step for assessing progress & guidance for subsequent work.

Role of the Sub committee of planned maintenance

Study how development.

to advance Instruct how to advance Kaizen.

the phase Kobetsu Instruct how to horizontally replicate TPM Standardization of various items and information exchange

Role of the Sub committee of initial flow control

- Study cases - Review existing system - Standardize various items - To optimize life cycle cost, as well to improve equipment reliability by Maintenance prevention design.

Role of the Sub committee of Quality Maintenance

- Study of Himanshitu techniques Instruct how Himanshitu-Hozen to advance - Instruct how to horizontally replicate TPM - Standardization of various items and information exchange

Role of the Sub Committee of office improvement

- Study how to advance the step development - Instruct how to advance Kobetsu Kaizen - Instruct how to horizontally replicate TPM - Standardization of various items and information exchange

Role of the Education and training committee

- Work out the training plan - Check the promotion progress and review problem

Role of the Safety and Hygiene Committee

- Educating Safety and Hygiene systems - Control of safety and Hygienic condition

TPM Implementation Steps

      Building Management will Establishing common TPM Language Announcement by top Management Introductory Education and campaign Work Environment the 5S Establishing TPM promotion organization and setting up model equipment.

  Setting basic policy and Target for TPM Creation of Master Action Plan TPM kick off Cont..

TPM Implementation Steps

 Establishing systems production efficiency a. Problem Solving Tools Training on Tools for improving Continuous application of tools b. Waste Elimination c. Kaizen d. Autonomous Maintenance e. Planned Maintenance f. Education and Training Cont..

TPM Implementation Steps

      control MP Design and equipment initial Quality maintenance Office TPM Safety, hygiene and pollution control Measuring and Monitoring Management – Visual Preparation for PM excellence award by JIPM JIPM Final Assessment excellence award.

for PM

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Major Losses

Shutdown Losses Production Losses Equipment failure Losses Process failure Losses Normal Production Losses Abnormal Production Losses Quality Defect Losses Reprocessing Losses Management Losses Motion Losses Line Organization Losses Cont.

Major Losses

- Losses resulting from lack of automated system - Measurement Losses - Yield Losses - Energy Losses - Die, Jigs and tools Losses

The common functions of all the Pillars

- Objectives of TPM - Goals of TPM - Implementation Plan for TPM - Loss Structure - TPM Promotion Committees Minutes of meeting of Promotion Committees/Action Plan - Processes/Sub-Processes TPM Audits TPM

Focused Improvement

includes all activities that maximize the overall effectiveness of equipment, processes and plant through elimination of losses and improvement of performance. The overall Plant effective (OPE) is calculated as follows: OPE= Availability of Plant Performance Rate x Quality Rate x

Focused improvement

Implementation Steps Registration of Improvement Topic Improvement Targets I mplementation Plan for the Topic Results of Improvement Focused Improvement Audit

Autonomous maintenance

This emphasizes the need for individual workers to carry out routine inspection, oiling, repairs, detection of abnormalities of their own equipments for the purpose of “Protecting their own equipment”.

Autonomous maintenance

Implementation Steps Autonomous Activities Autonomous Maintenance Tags Autonomous Maintenance Standards One Point Lessons Equipment Evaluation Criteria Equipments Maintenance for Autonomous Abnormalities and Counter measures Visual Controls Cont..

Autonomous maintenance

Analysis of MTBF (From Plant Maintenance Module) Audit Autonomous Maintenance

Plant Maintenance

- Implementation Steps - Equipment Data Base, Specifications and Configuration - Maintenance Activities, Spares Required, Procedure, Safety Precautions - Break Down Maintenance - Planned (Time Based Maintenance) - Opportunity Maintenance - Lubrication Schedule - Inspection Schedule - Calibration of Instruments Cont..

Plant Maintenance

Shut Down Maintenance - Reading of various equipments (Condition Based Maintenance) Resources Maintenance required/consumed - History of Maintenance/Log Books - Budget Vs. Actual cost of Maintenance for - Planned Maintenance Audit

Office Maintenance

- Office Functions - File/Document Analyzing Forms - Office Function work Method - Daily Work Survey - Work Allocation - Daily/Monthly work summary - Monthly load Chart

Product Design and Equipment Initial Control

- Aims - Product Information Points - Life Cycle Cost - Product Design Information Sheet

Quality Maintenance

- Quality Maintenance Aims - Quality Defect Factors - Steps of Quality Maintenance - Present Status of Process - Process which cause defects Analysis of 4M(Man, Machine, Material and Method) - Countermeasures Conditions for 4M that do not produce defects - Checking Methods - Standards Cont..

Quality Maintenance

- Quality Improvement Results Defect Rate (From Lab Test Module) Customer Complaint Rate Customer Feed Back Module) (From Reprocessing Rate (From Production Module) - Quality Variation (From Lab Test Module)

Worker’s Education & Training

- Training needs Worker’s Skills - Training Programs - Training Schedules - Training Infrastructure - Faculty - Training Cost - Feedback - Training Budget/Utilization

Safety, Hygiene & Environment Control

- Accidents - Safety Training, first aid, emergency handling Procedure - Safety Manuals - Health Check up of Employee - Pollution Control Checks and Results - Drinking Water Tests - Safety Audit - Hygiene Audit

Customer Feed Back

- Feed Back Type Receipt of Back/Complaint Customer Feed - Customer Complaint Response, solution, action - Effect of Complaints