TPM(Total Productive Maintenance)

TPM(Total Productive Maintenance):

                           Total Productive Maintenance (TPM) is a system of maintaining and improving the integrity of production, safety and quality systems through the machines, equipment, processes, and employees that add business value to an organization.

 

               TPM is not a responsibility of maintenance department only, rather it’s implemented by all employees:

1.  Maintenance  
2. Operations 
3.  Design & Project Engineering  
4. Construction Engineering
5. Inventory and Stores  
6. Purchasing
7. Accounting and Finance 
8. Plant and Site Management  
9. Other

 

                   The main objective of Total Productive Maintenance (TPM) is to improve overall productivity by optimizing equipment availability.

         

8 Pillars of TPM

1. Autonomous Maintenance

2. Planned Maintenance

3. Quality Maintenance

4. Focused Improvement

5. Early Equipment Management

6. Training and Education

7. Safety,Health & Environment

8. TPM in administration

  The three Goals of TPM:

1. Zero unplanned failures

2. Zero product defects

3. Zero accident           

 8 Pillars of Activity

 Total productive maintenance(TPM) increases productivity,efficiency and safety by empowering operators,team leaders and managers to all play a proactive role in the day to day operation and maintenance of their own work areas through 8 pillars of acivity.

 Discuss about 8 pillars of TPM

Pillar 1: Autonomous Maintenance|What is Autonomous Maintenance|

         Places responsibility for routine maintenance, such as cleaning, lubricating, and inspection, in the hands of operators.

How does autonomous maintenance help?   

• Gives operators greater “ownership” of their equipment.
• Increases operators’ knowledge of their equipment.
• Ensures equipment is well-cleaned and lubricated.
• Identifies emergent issues before they become failures. 
• Frees maintenance personnel for higher-level tasks.

Pillar 2: Planned Maintenance|What is Planned Maintenance|

 Schedules maintenance tasks based on predicted and/or measured failure rates       

How does planned maintenance help?

•  Significantly reduces instances of unplanned stop time.
• Enables most maintenance to be planned for times when equipment is not scheduled for production.
• Reduces inventory through better control of wear-prone and failure-prone parts.

 Pillar 3: Quality Maintenance |What is Quality Maintenance|      

Design error detection and prevention into production processes. Apply Root Cause Analysis to eliminate recurring sources of quality defects. 

How does quality maintenance help?

• Specifically targets quality issues with improvement projects focused on removing root sources of defects.
• Reduces number of defects.
• Reduces cost by catching defects early (it is expensive and unreliable to find defects through inspection).

Pillar 4: Focused Improvement|What is focused improvement|

          Have small groups of employees work together proactively to achieve regular, incremental improvements in equipment operation. 

How does focused improvement help?

•  Recurring problems are identified and resolved by cross -functional teams.
• Combines the collective talents of a company to create an engine for continuous improvement.

Pillar 5: Early Equipment Management |What is Early Equipment Management|   

Directs practical knowledge and understanding of manufacturing equipment gained through TPM towards improving the design of new equipment.    

How does early equipment management help?

Pillar 6: Training and Education |What is Training and Education|

Fill in knowledge gaps necessary to achieve TPM goals. Applies to operators, maintenance personnel and managers.       

How does training and education help?

• Operators develop skills to routinely maintain equipment and identify emerging problems.
• Maintenance personnel learn techniques for proactive and preventative maintenance.
•  Managers are trained on TPM principles as well as on employee coaching and development.

Pillar 7: Safety, Health, Environment |What is Safety, Health, Environment|

 Maintain a safe and healthy working environment.       

How does safety,health & environment help?

•  Eliminates potential health and safety risks, resulting in a safer workplace.
• Specifically targets the goal of an accident-free workplace.

Pillar 8: TPM in Administration |What is TPM in Administration|

Apply TPM techniques to administrative functions.        

How does TPM in administration help?

• Extends TPM benefits beyond the plant floor by addressing waste in administrative functions.
• Supports production through improved administrative operations (e.g. order processing, procurement, and scheduling). 

Benefits

 1. Less unplanned maintenance time

           Aerospace industry supplier MRC Bearings were able to achieve almost a 98 per cent reduction in unplanned maintenance hours within eight months of introducing a TPM program

2. A safer working environment

 The TPM model is made up of a 5S foundation, ensuring all workspaces are sorted, ordered, clean, and standardized at all times, and eight supporting activities, all of which result in a safer workplace.

3. Increased quality output

          One of TPM’s supporting activities or ‘pillars’ is Quality Maintenance, which integrates quality improvements into the production process.

4. Proven impact

   Improves Overall Equipment Effectiveness (OEE) score - the gold-star standard for rating manufacturing productivity and TPM’s major goal of achieving ‘perfect production’ (no breakdown, no small stops or slow running, no defect, no accident) is approached.

 

T         PM reduces the six big losses as below:

Six Big Losses	OEE Category	Examples	Comments
Unplanned Stops	Availability Loss	Tooling Failure, Unplanned Maintenance, Overheated Bearing, Motor Failure	There is flexibility on where to set the threshold between an Unplanned Stop (Availability Loss) and a Small Stop (Performance Loss).
Setup and Adjustments	Availability Loss	Setup/Changeover, Material Shortage, Operator Shortage, Major Adjustment, Warm-Up Time	This loss is often addressed through setup time reduction programs such as SMED (Single-Minute Exchange of Die).
Small Stops	Performance Loss	Component Jam, Minor Adjustment, Sensor Blocked, Delivery Blocked, Cleaning/Checking	Typically only includes stops that are less than five minutes and that do not require maintenance personnel.
Slow Running	Performance Loss	Incorrect Setting, Equipment Wear, Alignment Problem	Anything that keeps the equipment from running at its theoretical maximum speed.
Production Defects	Quality Loss	Scrap, Rework	Rejects during steady-state production.
Reduced Yield	Quality Loss	Scrap, Rework	Rejects during warm-up, startup or other early production.

 

Measuring the TPM outcome(OEE)

The OEE rating is calculated using three main reasons for productivity loss: Availability, Performance and Defects. These are directly tied to TPM’s goals of no breakdowns, no stops and no defects:

 

OEE score (where 100%= Perfect Production) 

=

Availability (no breakdowns) 

      X

Performance (no small stops or slow running)

                                            X

Quality (no defects)

TPM Roadmap

 1. Identify Pilot Area
 2. Restore Equipment to Prime Operating Condition
 3. Start Measuring OEE
 4. Address Major Losses
 5. Introduce Proactive Maintenance Techniques 
 6. Additional TPM Activities
 7. Sustainable Improvement

Practical work on TPM

 Repair Code

Repair code	Repair description
B001	Thread breakage
B002	Skip Stitch
B003	Puckering
B004	Tension setting
B005	Trimmer Adjust
B006	Oil Leakage
B007	Machine Jam
B008	Motor Repair
B009	Needle broken
B010	Needle mark
B011	Shining
B012	Needle cut
B013	Folder adjust
B014	Parts change
B015	P C Board error
B016	Power supply problem
B017	Needle bar shaking
B018	Pressure foot change
B019	Needle Plate Change
B020	Feed dog adjustment
B021	Broken Stitch
B022	Motor Belt Changing
B023	Looper Change
B024	Fuel filter change
B025	Battery problem
B026	Radiator water problem
B027	ECU problem
B028	water separator filter problem
B029	fuel pump problem
B030	radiator fan belt problem
B031	High temperature problem
B032	Non return valve problem
B033	check valve problem
B034	safety valve problem
B035	solenoid valve problem
B036	High voltage transforma problem
B037	water controller problem
B038	Relay
B039	Panel problem-M/D
B040	Belt adjusting-M/D
B041	Belt Damage-M/D
B042	Belt& M/D clean
B043	Motor Problem-F/I
B044	Belt Broken-F/I
B045	Belt Damage-F/I
B046	Lighting Problem-F/I
B047	Glue show at top part F/U
B048	Motor problem-F/U
B049	Hit Adjusting F/U