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TKL KNITS (INDIA) PVT LTD

TPM – Total Productive
Maintenance

TKL KNITS (INDIA) PVT LTD

TPM?
 Total Productive Maintenance (TPM) is a system of
maintaining and improving the integrity of
production and quality systems through the
machines, equipment, processes, and employees
that adds Value to an organization.
 TPM focuses on keeping all equipment in top
working condition to avoid breakdowns and delays
in manufacturing processes.
TPM Objective:
 Main Objective of TPM is to increase the productivity of a
factory and its equipment with a modest investment in
maintenance.
 Next Main Objective of TPM is to increase the Overall
Equipment Effectiveness of plant equipment
Pillars of TPM:
The eight pillars of TPM are mostly focused on proactive and
preventive techniques for improving equipment reliability
 Autonomous Maintenance
 Focused Improvement
 Planned Maintenance
 Quality management
 Early equipment management
 Education and Training
 Safety Health Environment
 Administrative & office TPM
Pillars of TPM:
Pillar What Is It? How Does It Help?
Autonomous Places responsibility for routine •Gives operators greater “ownership” of their equipment.
Maintenance maintenance, such as cleaning, •Increases operators’ knowledge of their equipment.
lubricating, and inspection, in •Ensures equipment is well-cleaned and lubricated.
the hands of operators. •Identifies emergent issues before they become failures.
•Frees maintenance personnel for higher-level tasks.

Planned Maintenance Schedules maintenance tasks •Significantly reduces instances of unplanned stop time.
based on predicted and/or •Enables most maintenance to be planned for times when equipment is
measured failure rates. not scheduled for production.
•Reduces inventory through better control of wear-prone and failure-prone
parts.

Quality Maintenance Design error detection and •Specifically targets quality issues with improvement projects focused on
prevention into production removing root sources of defects.
processes. Apply Root Cause •Reduces number of defects.
Analysis to eliminate recurring •Reduces cost by catching defects early (it is expensive and unreliable to
sources of quality defects. find defects through inspection).

Focused Have small groups of •Recurring problems are identified and resolved by cross-functional teams.
Improvement employees work together •Combines the collective talents of a company to create an engine for
proactively to achieve regular, continuous improvement.
incremental improvements in
equipment operation.
Pillars of TPM:
Pillar What Is It? How Does It Help?
Early Equipment Directs practical knowledge •New equipment reaches planned performance levels much faster due to
Management and understanding of fewer startup issues.
manufacturing equipment •Maintenance is simpler and more robust due to practical review and
gained through TPM towards employee involvement prior to installation.
improving the design of new
equipment.
Training and Fill in knowledge gaps •Operators develop skills to routinely maintain equipment and identify
Education necessary to achieve TPM emerging problems.
goals. Applies to operators, •Maintenance personnel learn techniques for proactive and preventative
maintenance personnel and maintenance.
managers. •Managers are trained on TPM principles as well as on employee
coaching and development.
Safety, Health, Maintain a safe and healthy •Eliminates potential health and safety risks, resulting in a safer
Environment working environment. workplace.
•Specifically targets the goal of an accident-free workplace.

TPM in Apply TPM techniques to •Extends TPM benefits beyond the plant floor by addressing waste in
Administration administrative functions. administrative functions.
•Supports production through improved administrative operations (e.g.
order processing, procurement, and scheduling).
OEE( Overall Equipment Effectiveness):
 OEE has three factors which are multiplied to give one
measure called OEE
Performance x Availability x Quality = OEE
 Each factor has two associated losses making 6 in total,
these 6 losses are as follows:
 Performance = (1) running at reduced speed - (2) Minor
Stops
 Availability = (3) Breakdowns - (4) Product changeover
 Quality = (5) Startup rejects - (6) Running rejects
OEE( Overall Equipment Effectiveness):
OEE( Overall Equipment Effectiveness):
Component TPM Goal Type of Productivity Loss
Availability No Stops Availability takes into account Availability Loss, which includes
all events that stop planned production for an appreciable length
of time (typically several minutes or longer). Examples include
Unplanned Stops (such as breakdowns and other down events)
and Planned Stops (such as changeovers).

Performance No Small Stops or Slow Performance takes into account Performance Loss, which
Running includes all factors that cause production to operate at less than
the maximum possible speed when running. Examples include
both Slow Cycles, and Small Stops.

Quality No Defects Quality takes into account Quality Loss, which factors out
manufactured pieces that do not meet quality standards, including
pieces that require rework. Examples include Production Rejects
and Reduced Yield on startup.

OEE Perfect Production OEE takes into account all losses (Availability Loss, Performance
Loss, and Quality Loss), resulting in a measure of truly productive
manufacturing time.
Thank You!!!