Total productive maintenance
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This document discusses Total Productive Maintenance (TPM), a maintenance program that aims to increase production while improving employee morale. TPM originated in Japan in the 1950s and was introduced to reduce waste and costs, maintain product quality with fewer defects, and deliver goods to customers on time. The document outlines the types of maintenance as breakdown, preventive, and predictive and explains the goals of TPM are to achieve 80% equipment performance, 90% overall equipment effectiveness, and reduce manufacturing costs by 30% through employee involvement in maintenance.
Total productive maintenance
- 2. INTRODUCTION WHY TPM? TPM HISTORY TYPES OF MAINTENANCE BENEFITS OF TPM THE SIX LOSSES
- 3. It can be considered as the medical science of machines. Total productive maintenance(TPM) is a maintenance program which involves a newly defined concept for maintaining plants and equipments. The goal of the TPM program is to markedly increase production while, at the same time, increasing employee morale and job satisfaction. TPM brings maintenance into focus as a necessary and vitally important part of the business. It is no longer regarded as a non-profit activity. Down time for maintenance is scheduled as a part of the manufacturing day and, in some cases, as an integral part of the manufacturing process.
- 4. TPM was introduced to achieve the following objectives. The important ones are listed below; Avoid wastage in a quickly changing economic environment. Producing goods without reducing product quality. Reduce cost. Produce a low batch quantity at the earliest possible time. Goods send to the customers must be non defective.
- 5. TPM is a innovative japanese concept. The origin of TPM can be traced back to 1951 when preventive maintenance was introduced in Japan. However the concept of preventive maintenance was taken from USA. Nippondenso was the first company to introduce plant wide preventive maintenance in 1960. preventive maintenance is the concept wherein, operators produced goods using machines and the maintenance group was dedicated with work of maintaining those machines, however with the automation of Nippondenso, maintenance become a problem as more maintenance personnel were required. So the management decided that the routine maintenance of equipment would be carried out by the operators. (This is autonomous maintenance, one of the features of TPM). Maintenance group took up only essential maintenance works.
- 6. Obtain minimum 80% OPE. Obtain minimum 90% OEE(Overall Equipment Effectiveness) Run the machines even during lunch.( lunch is for operators and not for machines!) Operate in a manner, so that there are no customer complaints. Reduce the manufacturing cost by 30%. Achieve 100% success in delivering the goods as required by the customer. Maintain an accident free environment. Increase the suggestions by 3 times.
- 7. BREAKDOWN MAINTENANCE: It means that people waits until equipment fails and repair it. Such a thing could be used when the equipment failure does not significantly affect the operation or production or generate any significant loss other than repair cost. PREVENTIVE MAINTENANCE: It is a daily maintenance ( cleaning, inspecting, oiling and re- tightening), design to retain the healthy condition of equipment and prevent failure through