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T PM Awareness

Total Productive Maintenance (TPM) is a company-wide initiative aimed at maximizing equipment efficiency through establishing a total system of preventative maintenance involving all departments and personnel. The goals of TPM include achieving zero breakdowns, accidents, and defects to improve productivity, quality, cost, delivery performance, safety, and employee morale. TPM utilizes various pillars like planned maintenance, autonomous maintenance, quality maintenance, and education and training to identify issues, implement solutions, and empower employees. A case study demonstrates how a company applied TPM principles to transition from a wet expansion process for teflon parts to a more efficient dry expansion process.

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shariq warsi
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94 views28 pages

T PM Awareness

Total Productive Maintenance (TPM) is a company-wide initiative aimed at maximizing equipment efficiency through establishing a total system of preventative maintenance involving all departments and personnel. The goals of TPM include achieving zero breakdowns, accidents, and defects to improve productivity, quality, cost, delivery performance, safety, and employee morale. TPM utilizes various pillars like planned maintenance, autonomous maintenance, quality maintenance, and education and training to identify issues, implement solutions, and empower employees. A case study demonstrates how a company applied TPM principles to transition from a wet expansion process for teflon parts to a more efficient dry expansion process.

Uploaded by

shariq warsi
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPT, PDF, TXT or read online on Scribd
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Total Productive Maintenance

Total Productive Maintenance is a company wide


improvement initiative which is achieved by :
DEFINITION OF TPM ( PRODUCTION TPM )

What is TPM?

1. To set a goal to maximise equipment efficiency


(overall efficiency).
2. By establishing a total system for PM for the
entire life of equipment.
3. Participation by all departments, including
equipment planning, operating and
maintenance departments.
4. Involving all personnel, including top personnel
to first-line operators.
5. For promoting PM by motivation management,
namely, by autonomous small-group activities.
Why TPM is required ?

TPM is a TOOL used in industries for better functioning of


various
Department in an organization or simply better functioning of an
Organization/Industry

For simple under standing we say TPM means “zero BAD”

TPM is required for achieving “zero BAD”:

B – Breakdowns.

A – Accidents.

D – Defects.
Targets of TPM :-

PRODUCTIVITY

QUALITY

COST

DELIVERY (100% as per schedule)

SAFETY

MORALE
Various Pillars under TPM.

KK pillar ( Kobetsu kaizen ) : Individual development,


This pillar basically focus on the development or
improvement of the plant or concerned area .

PM pillar (Planned maintenance) : This pillar plans the


maintenance activities.

DM pillar (Development management) : Not in use yet.


It manages the development in various sector of an
organization.

E&T pillar (Education & training ) : Under this pillar skills


of the employees are empowered.
JH pillar( Jishu hozen) : Autonomous maintenance ,
This pillar follows the “CLITA” activities.
C – cleaning
L – lubrication
I – inspection
T – tigtening
A – adjustment

QM pillar (Quality maintenance) : Quality maintenance

OFFICE TPM : Maintaining good house keeping(5S) in


in office area. Developing some improvements in office area
Which would response against PQCDSM .

SHE pillar (safety, health & environment) : This pillar concentrates


on safety , health & environment of the plant & employees.
Effectiveness of TPM

P…..Productivity improvement ----------------------------------------------1.5 to 2 times


 Reduction in Number of Sporadic Failures-----------------1/10 to 1/250

 Equipment Operating--------------------------------------------1.5 to 2 times

Q…..Reduction in Product Defects-----------------------------------------1/10


Reduction in Customer Claims--------------------------------------1/4

C…..Reduction in Maintenance Cost---------------------------------------30%


D…..Reduction in Product Inventories--------------------------------------0
S….. Reduction in Accident, Elimination of Pollution------------------0

M…..Increase in Number of Employee Suggestions--------------------5 to 10 times


CASE STUDY
Teflon mandrel

Molded piece Expanded piece

Stand
Application of oil on Teflon mandrel.
Shed expansion
Vati placed on the shed
No. of pieces exp. (vati exp.)
JH PILLAR

ABNORMALITIES ENCOUNTERED DURING THE JH ACTIVITY WHERE:

• FATIGUE TO OPERATOR

• UNCLEAN SURFACE ON WHICH THE PRODUCTS WERE PLACED

• DUE TO OPEN SPACE OR SURROUNDING AREA ENTRAPMENT OF DUST


PARTICALS ON THE PRODUCT.SURFACE.

• INCLUSIONS ON THE SURFACE DUE TO OPEN SURROUNDING & COOLING IN


WATER.

• DUE TO USE OF LIQUID FOR EXP. FOREIGN PARTICALS STICKING ON THE MANDRELL
& CAVITIES , RESULTING PIN HOLES ON THE SURFACE.
KK PILLAR (KOBETSU KAIZEN)

PROBLEM AREA : WET EXPANSION

KAIZEN IDEA : ELIMINATED THE WET EXP. &


INTRODUCTION OF DRY EXP.IN ITS PLACE .
Dry exp. machine
Mandrel, cooling unit, cavity plate, cylinder.
PM PILLAR

COMISSIONING OF THE
M/C AND HANDING OVER TO
PRODUCTION (JH)
QM Pillar.
Quality specification.
QM PILLAR
QM PILLAR
QM PILLAR
E&T PILLAR :

TRAINING THE OPERATOR ACCORDING TO SOP :

(EXAMPLES):-

•SETTING THE TEMPERATURE OF THE OVEN.

• SELECTING THE REQUIRED CAVITY PLATE.

• CHECKING AIR PRESSURE OF THE MANDRELL

• SETTING TEMP. OF AIR CONDITIONER FOR COOLING THE PIECE

•OTHER FEATURES OF THE M/C.


THANK YOU

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