Total Productive Maintenance

1. Total Productive Maintenance SARA Infotech (P) Ltd. Bombay, India.

2. 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

3. 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.

4. TPM Goals • Achieve zero breakdowns & zero losses thru -Focused Improvement, -Effective Equipment Management Techniques - Autonomous Maintenance Systems. Cont.

5. TPM Goals • Prevent losses before they occur thru -Integrated functions of production - Maintenance - Technical - Commercial - Administration - Finance - Marketing. Cont.

6. TPM Goals • Achieving zero defects, to - become a consistent supplier of quality products and services - conform customer specifications. Cont.

7. TPM Goals • Give effective training to • develop highly skilled, motivated and self-reliant workforce. • Prolong life span of equipment by maintainability improvement. Cont.

8. 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.

9. TPM Goals • TPM ensures a working environment that is - Clean -Accident free - Pollution free Cont.

10. 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

11. Role of TPM Promotion Committee - Basic policy and Target Setting - Audit of the promotion progress and the 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.

12. Role of the Plant Promotion Committee - Workout the plan to promote Jishu-Hozen and Kobetsu-Kaizen and check the progress of promotion activities. - Review problems and give instructions to small groups - Organize Kobetsu-Kaizen project teams.

13. 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.

14. 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.

15. Role of the Sub-committee of planned maintenance -Study how to advance the phase development. -Instruct how to advance Kobetsu-Kaizen. -Instruct how to horizontally replicate TPM Standardization of various items and information exchange

16. 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.

17. Role of the Sub-committee of Quality Maintenance - Study of Himanshitu techniques - Instruct how to advance Himanshitu-Hozen - Instruct how to horizontally replicate TPM - Standardization of various items and information exchange

18. 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

19. Role of the Education and training committee - Work out the training plan - Check the promotion progress and review problem

20. Role of the Safety and Hygiene Committee - Educating Safety and Hygiene systems - Control of safety and Hygienic condition

21. 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..

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

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

24. 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.

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

26. 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 TPM Promotion Committees/Action Plan -Processes/Sub-Processes TPM Audits

27. 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 x Performance Rate x Quality Rate

28. Focused improvement -Implementation Steps - Registration of Improvement Topic -Improvement Targets -    Implementation Plan for the Topic -Results of Improvement - Focused Improvement Audit

29. 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”.

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

31. Autonomous maintenance -Analysis of MTBF (From Plant Maintenance Module) - Autonomous Maintenance Audit

32. 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..

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

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

35. Product Design and Equipment Initial Control -Aims -Product Information Points -Life Cycle Cost - Product Design Information Sheet

36. 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..

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

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

39. 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

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