Session9.pptx

7/29/2019 Session9.pptx

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LSS Session 9

Total Productive Maintenance (TPM)


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The origin

TPM developed by the Japan Institute ofPlant Maintenance

Focus

Increased production, while Increasing employee morale & Job satisfaction

An approach with the goal of

Zero breakdowns Zero breakdowns Zero accidents

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Objectives of TPM

TPM aims to maximize overall equipmenteffectiveness (OEE)

TPM establishes planned maintenance forlifetime of machinery / equipment

Need for cross functional teams

All employees are involved Planned maintenance is enabled through

small autonomous groups

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Overall equipment effectiveness model

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OEE

Availability

Breakdown

Set up & Adjustment

Performancerate

Reduced Speed

Idling & minor stoppage

Quality rateRejects & rework

Start up


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Metrics for equipment performance

Availability = (Loading time downtime)/downtime

Performance efficiency = (Theoreticalcycle time x Units produced )/(Loadingtime downtime)

Quality rate (QR) = (Actual Productionvolume

Defective outputs) / Actual

production volume

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Eight Pillars of TPM

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Pillar 1:Jishu Hozen (AutonomousMaintenance)

Train operators to handle minormaintenance issues

Operators take ownership for theirmachines, equipment and tools

Focus on elimination of defects at source

Inspection, standardization are alsointegral part of this stage

Kaizen could also be involved in this stage

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Pillar 2: Individual Improvement

Kobetsu Kaizen Also termed as focused improvement Target is to work towards zero-losses

especially in downtime, breakdowns Major Losses

1. Breakdowns2. Start-up losses

3. Speed loss4. Defect losses5. Set up change losses

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Pillar 3: Planned Maintenance

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Preventive Maintenance: Set schedules for maintenance activity

Daily maintenance: establish daily hygiene

Predictive maintenance condition based, depends on knowledge

Breakdown maintenance: unavoidable, depends on failure

Corrective maintenance: modifications in equipment, tooling, etc


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Pillar 4: Quality Maintenance

It is aimed at customer delight throughdefect-free operations

How is it different from the earlierprinciples?

Focuses on in-line detection

Usespoka-yoke methods

Segregation of defects

Quality assurance

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Pillars 5-8

5. Education & Training Phase 1: Do not know Phase 2: Know the theory, but cannot do Phase 3: Can do but cannot teach Phase 4: Can do and also teach

6. Development Management Reduction in time taken to receive, install and set-up

new machinery

7. Safety Health and Environment Zero accidents, zero health damage and zero fires

8. Office TPM Efficiency in administrative functions

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TPM Club of India

CII associated with JIPM to set up the TPMclub in 1998

Objectives of the club To promote TPM in the Indian industryAssist industry to implement TPM through

training and consultancy CII-TPM club has been accredited as the

assessment agency for TPM awards

Indian recipients of the awards In 2008: Brakes India, Sundaram Industries,

Exide Industries

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THANK YOU

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Session9.pptx

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