TOTAL PRODUCTIVE MAINTENANCE
Definition • Maintenance is defined as the management, control, execution and quality assurance of activities which ensure the achievement of optimum availability and performance of a plant in order to meet business objectives.
TPM - Meaning • TPM is a partnership between the maintenance and production organization to improve product quality, reduce waste, reduce cost, increase equipment availability and improve maintenance state.
EVOLUTION OF MAINTENANCE 1940 1950 1960 1970 1980 1990 2000
TYPES OF MAINTENANCE • Corrective (or) breakdown maintenance It implies that repairs are made after failure of machine or equipment • Scheduled (or) Routine maintenance It is a stitch-in-time procedure aimed to avoiding breakdowns
TYPES OF MAINTENANCE • Preventive maintenance It is carried out before the failure arises (or) prior to the equipment actually breakdowns. E.g. Overhauling & Periodic upkeep. • Predictive maintenance Equipment Condition evaluated periodically and maintenance carried out.
OBJECTIVES OF TPM • Improve Equipment Effectiveness • Achieve Autonomous • Plan Maintenance • To Train all staff in maintenance skills • To Zero Breakdowns
Cost Trade-off Between PM & CM 1000 C o s t i n R u p e e s 650 Total cost of maintenance Maintenance Activity Costs (PM) 500 Breakdown Penalty costs (CM) 50 0 LOW MEDIUM MAINTENANCE HIGH
BENEFITS • Increased productivity • Equipment reliability • Reduced down time • Increased plant capacity • Low production maintenance costs • Team work Between Production & Maintenance People • Improved safety & Profit