TPM Over View
TPM Over View
CM MP
(1957) PRODUCTIVE MAINT. (1960)
(3)
PROD. (2)
TOTAL (1)
MAINT.+ ECONOMIC
AUTO. SYSTEM
EFFICIENCY
MAINT.
( PM-CM-
(SMALL MP)
GROUP ( PM )
ACTIVITIES)
FEATURES OF TPM
FEATURES OF PRODUCTIVE
MAINTENANCE
FEATURES OF PREVENTIVE
MAINTENANCE
SPREAD OF TPM
Consumer Electronics,
Micro Electronics,
M/C Tools, Plastics, Films etc..
UK 11
EUROPE FRANCE 5
NORTH AMERICA GERMANY
ITALY
4
3
SPAIN 1
SWEDEN 1
NETHERLAND 1
BELGIUM 1
EUROPE TURKEY 1
NORTH U.S.A. 12
AMERICA CANADA 1
BRAZIL 6
ASIA SOUTH
AMERICA
ARGENTINA 3
CHILE 1
PRODUCTVITY, QUALITY,
INVESTMENT IN COST , DELIVERY
EQUIPMENT
SAFETY &
MORALE
MAINTENANCE UTILITY
MANAGEMENT
METHOD
INPUT OUTPUT
PRODUCTION EFFICIENCY IN TPM
Production
Production =
Efficiency Cost
Simultaneously
From TPM of Production Department to Company-wide
TPM Covering All Company Activities
Top Management
Genera
Planning Financial Personnel
l Affairs
Administrativ
e
Development
Production of products & Sales
equipments
Plant Plant Plant Plant
TPM Phase 1
TPM Phase 2
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TPM 8 Pillar Approach
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Typical TPM Organization Chart
President
TPM Promotion Office
Members:
• Staff / Manager
Activities:
• Understanding the 16 major losses
• Calculating and settling goals for overall equipment
efficiency, productivity and production subsidiary resources
• Implementation of PM analysis
• Thorough pursuit of equipment and production “as it
should be”.
Autonomous Maintenance
Purpose:
•Training of operators for proficient in equipment
• Maintaining one’s own equipment self
Members: Operator, Line Leader
Activities: Implementation of 7 steps
1. Initial clean-up
2. Countermeasures for the source of problems and
measures for difficult-to- access locations
3. Creation of tentative autonomous maintenance
standards
4. General inspection
5. Autonomous inspection
6. Standardization
7. All-out goals management
Planned Maintenance
Purpose:
• Improving efficiency of maintenance departments to
prevent 8 major losses
Members:
• Manager and maintenance men of maintenance department
Activities:
• Daily Maintenance
• Time Based Maintenance
• Condition Based Maintenance
• Improvement for increasing the service life expectancy
• Control of replacement parts
• Failure analysis and prevention of recurrence.
• Lubrication control
Quality Maintenance
Purpose:
Achieve zero defects by supporting and maintaining
equipment conditions
Members: Quality assurance Staff, Production engineering staff, Manager
Activities:
• Verify quality characteristics standards; understand defect
phenomena and performance
• Investigating the conditions for building quality, processes
and raw materials, equipment and methods
• Investigating, analysing and improving the conditions of
malfunctions
• Setting 3M conditions, setting standard values for inspection
• Creation of standards that can be followed; trend
management
Development Management
Purpose:
• Reducing product development and prototyping time
• Reducing the development, design and fabrication time of equipment
• Improving 1-shot start-up stability of products and equipment
Members: Research and development staff, Production engineering
staff, Maintenance staff
Activities:
•Setting development and design goals
•Ease of production
•Ease of QA Implementation
Reflect in MP design
•Ease of use
•Ease of maintenance
•Reliability
•Investigate LCC
•Design release drawing
Production: Identify problems in the prototype, trial run and initial-
phase mass production control stages.
Office TPM
Purpose:
• Achieve zero function losses
• Creation of efficient offices
• Implementation of support functions for production departments
Members:
•Leaders and members of administration/Indirect departments
Activities:
•Autonomous maintenance activities
1. Initial clean-up (personal space)
2. Work inventory
3. Countermeasure for problems
4. Standardization
5. Promotion of autonomous management activities of work
• Individual improvement through project activities
1. Shortening of settlement schedule
2. Improvement of distribution
3. Improvement of purchasing and subcontracting
4. Reform of production control system
Education and Training
Purpose:
• Establishment of technical education for operations and
maintenance workers
Members:
•Operators
•Maintenance workers
Activities:
•Basic process of maintenance
•Tightening nuts and bolts
•Aligning keys
•Maintenance of bearings
•Maintenance of conductive parts
•Prevention of leaks
•Maintenance of oil pressure and air pressure equipment
•Maintenance of electrical control equipment
Safety and Health
Purpose:
• Achievement and support of zero failures
• Creating a healthy and safe workplace that gives meaning to work
Members:
• Safety, health and environment managers and specialised committee membe
• Staff specialising in safety and health
Activities:
• Measures to improve equipment safety
• Measures to improve work safety
• Improvement of work environment (noise, vibration and odors)
• Measures to prevent pollution
• Creation of healthy employees
• Promotion of invigorating activities
FUNCTIONS OF VARIOUS TPM COMMITTEES
TPM STEERING
COMMITTEE
TPM EFFORTS ON
RIGHT TRACK
• HORIZONTAL REPLICATION
EXAMPLE OF BASIC TPM POLICY
& GOALS
APPROACH
•TEAM APPROACH •TOTAL CUSTOMER
•OWNERSHIP SATISFACTION
•TOTAL EMPLOYEES •REWARDS &
PARTICIPATION RECOGNITION
•REGULAR REVIEW
PRODUCTIVITY --- COMPANY-A
Company – A
(Incre ase w ith re spe ct to be nch m ark 1996-97)
2.00
1.75
No. of times
1.50
1.25
1.00
A vg. A pr'01 to 2001-2002
1996-97 1997-98 1998-99 1999-2000 2000-2001
O c t'01 (Target)
S eries 1 1.00 1.45 1.46 1.65 1.67 1.77 1.87
DOWNTIME TREND --- COMPANY-A
Downtime trend
700
664.08
600
500
400 321.68
300 168.46
200
76.25 55.63
100
0 6.5
1996-97 1997-98 1998-99 1999-2000 2000-01 2001-02 (till
date)
CUSTOMER COMPLAINTS --- COMPANY-A
Customer complaints Company – A
7
0
Apr'01 to
1996-97 1997-98 1998-99 1999-2000 2000-01
Sep''01
GOOD
GOOD
1
0.8
No. of Time s
0.6
0.4
0.2
0
2001-02(Till Target
1996-97 1997-98 1998-99 1999-2000 2000-01
Date) (2002-03)
Series1 1 0.84 0.85 0.81 0.81 0.81 0.78
SAFETY --- COMPANY-A
Safety Company – A
M A J O AR C C I D E N T S S T A T I S T I C S O F T H E P L A N T (E X C L D S M S )
51
60
NO. OF ACCIDENTS
50
40 22
30 22 17 17
20 5
10
0
1 9 9 6 -9 7 1 9 9 7 -9 8 1 9 9 8 -9 91 9 9 9 -2 0 0 20 0 0 0 -0 1 2 0 0 1 -
0 2 (T ill
Y E AR D a te )
WHAT TPM IS NOT?
• ONLY MAINT. DEPARTMENT’S ACTIVITY---NO
• TPM--- PRODUCTIVITY DRIVEN INITIATIVE
---ONLY MAINT CAN NOT DO
• MAINT.--- ASSET MANAGEMENT
• TPM---TOTAL PARTICIPATIVE MANAGEMENT
TPM SUCCESS FACTORS