IMPLEMENTATION OF TPM

B.RAJESH
15MM07

TOTAL PRODUCTIVE MAINTENANCE

T: TOTAL

Participation of all Employees.

Include all Departments, operation, equipment and process.

P: PRODUCTIVE

Pursue the maximization of efficiency of the production system by making all loses zero.
Zero accidents Zero defects Zero breakdowns.

M: MAINTENANCE

To improve the efficiency of the equipment.

Maintenance means the entire life cycle of the production system.

Maintenance is not only to repair and maintain the machines.

WHY WE NEED TPM ?

The major objectives of the TPM are :

Avoid wastage in quickly changing environment.

Reduce Cost of Manufacturing.

Produce a low batch quantity at the earliest possible time.

Goods send to Customers must be non defective

TPM OBJECTVES
1. Increase production while, at the same time, increasing employee morale and job
satisfaction.
2. Hold emergency & unscheduled maintenance to a minimum.
3. To provide the safe and good working environment to the worker.
4. Achieve Zero Defects, Zero Breakdown and Zero accidents in all functional areas
of the organization.
5. Involve people in all levels of organization.
6. Form different teams to reduce defects and Self Maintenance.

BENEFITS OF TPM
Increased Employee Morale
Increased Productivity
Improved Sharing and Working as a Team
Improved tidines and cleaning of the working place
Improved Product Quality
Improved Customer Satisfaction
Reduced Costs
Improved Delivery Time
Enhanced safety Records
Improved Image
Improved Reputation

TYPES OF MAINTENANCE

Breakdown Maintenance

Preventive Maintenancee

Periodic Maintenance

Predictive Maintenance

Corrective Maintenance

Maintenance Prevention

TPM TARGETS

PRODUCTION
I). Obtain Minimum 80% Overall Production Efficiency
ii). Obtain Minimum 90% Overall Equipment Effectiveness
iii). Run the Machine during lunchtime
QUALITY
Operate in a manner, so that there are no customer complaint
COST
Reduce the manufacturing cost as much as possible
DELIVERY
Achieve 100% success in delivering the goods as required by the customer
SAFETY
Maintain an accident free environment
MULTYTASK
Develop multiskilled & flexible workers.

PILLARS OF TPM

ROLES OF PRODUCTION AND

MAINTENANCE IN TPM

MEASUREMENT OF TPM
EFFECTIVENESS
Breakdown losses
Set-up and adjustment losses
Minor/idling stoppage losses
Reduced speed losses
Defect/rework losses
Start-up losses

CASE STUDY OF TPM

IMPLEMENTATION
Background information of the electronics manufacturing company
introduction-preparatory stage of TPM implementation
step 1. Establishment of TPM organization
Step 2. Organization of TPM office
Step 3. Introductory education and campaign
Step 4. Setting the policies for TPM
Step 5. Creation of master plan for TPM development
Execution stage of TPM
Step 6. TPM kick off:The purpose of TPM

CASE STUDY OF TPM

IMPLEMENTATION(CONT)

12 STEPS OF TPM IMPLEMENTATION

EXAMPLE FOR FAILURE MODE

ANALYSIS OF TPM MODEL

TANGIBLE BENEFITS FOR TPM

IMPLEMENTATION

Mean unit between assists (MUBA).

Number of improvements.

Number of one-point lesson (OPL).

Number of suggestions.

Training hours for skill level enhancement.

IMPROVEMENT IN MUBA THROUGH TPM.

IMPROVEMENT IN MUBA THROUGH

TPM. (CONT)

IMPROVEMENT IN MUBA THROUGH

TPM. (CONT)

PARETO DISTRIBUTION OF MACHINE STOPPAGES

AFTER THE IMPLEMENTATION OF TPM.

SUGGESTION, IMPROVEMENT
(KAIZEN), TRAINING

During the TPM implementation period, operator and technician were trained and
developed with skills and knowledge in maintenance.

This was the aim of TPM to train people to be highly skilled, motivated and selfreliant regarding knowhow of their equipment and process.

SUMMARY OF TPM
IMPLEMENTATION

Effective equipment management: There was about 83% improvement in

equipment productivity improvement after TPM implementation. Also, the
equipment stoppage rate was reduced from 517 to 89 times. This tremendous
improvement enhanced the equipment in both effectiveness and quality in product
produced.

Empowerment of employees: Empowering the workforce caused a development

of a bright, cheerful and relaxed workplace for production people. Growth of work
habits, technical skill development and promotion of cross-functional team created
an enthusiastic workforce to enhance the company in both competitive power and
image.

IMPLICATIONS OF THIS STUDY

This case study employed TPM methodology to improve equipment effectiveness

as well as the technical skills, morale of members participated in TPM.

This was not the first attempt that the company in this study implemented TPM but,
ultimately, the company succeeded to do so in the front-end process.

THANK YOU