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Group :. Awais Ghaffar BSME 01093 – 068 Owais Ahmed BSME 01093 – 033 Hafiz M. Ahmed BSME 01093 – 041 Zeeshan. Total Production Maintenance. TPM. Overview:. What is TPM ?.

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  1. Group : • Awais Ghaffar BSME 01093 – 068 • Owais Ahmed BSME 01093 – 033 • Hafiz M. Ahmed BSME 01093 – 041 Zeeshan

  2. Total Production Maintenance TPM

  3. Overview:

  4. What is TPM ? Total Productive Maintenance (TPM) is a maintenance program which involves a newly defined concept for maintaining plants and equipment.

  5. History • TPM is a innovative Japanese concept. • The origin of TPM can be traced back to 1951 when preventive maintenance was introduced in Japan.  • The preventive maintenance concept was taken from the Americans. • Nippondenso was the first company to introduce plant wide preventive maintenance in 1960. 

  6. Goal of TPM The goal of the TPM program is to markedly increase production while, at the same time, increasing employee morale and job satisfaction.

  7. Why TPM ? TPM was introduced to achieve the following objectives. • Producing goods without reducing product quality. • Reduce cost. • Increased Production Rate. • Goods sent to the customers must be non defective.

  8. Types of maintenance : • Breakdown Maintenance • Preventive Maintenance • Periodic • Predictive • Corrective Maintenance • Maintenance Prevention

  9. 1.Breakdown Maintenance : “It means that people waits until equipment fails and repair it.”

  10. 2.Preventive Maintenance : “It is a daily maintenance ( cleaning, inspection, oiling and re-tightening )” a) Periodic Maintenance : Time based maintenance which is done periodically. b) Predictive Maintenance : This is a method in which the service life of important part is predicted based on inspection.

  11. 3.Corrective Maintenance : “Equipment with design weakness must be redesigned to improve reliability or improving maintainability”

  12. 4.Maintenance Prevention : “It indicates the design of a new equipment”

  13. Pillars of TPM

  14. PILLAR 1 - 5S :

  15. PILLAR 2 Autonomous maintenance Policy : • Uninterrupted operation of equipments. • Flexible operators to operate and maintain other equipments. • Eliminating the defects at source through active employee participation.

  16. PILLAR 3 - KAIZEN : "Kai" means change, and "Zen" means good Kaizen Target : • Achieve and sustain zero loses with respect to minor stops, measurement and adjustments, defects and unavoidable downtimes.

  17. PILLAR 4 PLANNED MAINTENANCE : “It is aimed to have trouble free machines and equipments.” • This breaks maintenance down into 4 "families" or groups which was defined earlier. • Préventive Maintenance • Breakdown Maintenance • Corrective Maintenance • Maintenance Prévention

  18. PILLAR 5 QUALITY MAINTENANCE : Target : • Achieve and sustain customer complaints at zero • Reduce in-process defects • Reduce cost of quality

  19. PILLAR 6 - TRAINING : Policy : • Focus on improvement of knowledge, skills and techniques. • Training to remove employee fatigue and make work enjoyable.

  20. PILLAR 7 - OFFICE TPM : Office TPM and its Benefits : • Better utilized work area • Reduced manpower • Reduced inventory levels in all parts of the supply chain • Clean and pleasant work environment.

  21. PILLAR 8 SAFETY, HEALTH & ENVIRONMENT Target : • Zero accident. • Zero health damage. • Zero fires.

  22. Applications In Pakistan

  23. Conclusion: • Now a days TPM may be the only thing that stands between success and total failure for some companies. • It has been proven to be a program that works. •  It can be adapted to work not only in industrial plants, but in construction, building maintenance, transportation, and in a variety of other situations.

  24. References: • http://www.plant-maintenance.com/articles/tpm_intro.shtml • http://www.densopartsweb.com/100/TPM100StudyGuide.pdf • http://www.strategosinc.com/tpm_pillars_4.htm

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