INTENTINTENT

TO UPGRADE TO UPGRADE THE THE CAPABILITIES OF CAPABILITIES OF ALL COMPANY ALL COMPANY MEMBERS MEMBERS THROUGH THROUGH EDUCATION,TRAIEDUCATION,TRAIN-ING AND N-ING AND PARTICIPATIONPARTICIPATION

TPM

OBJECTIVEOBJECTIVE

TO RESTRUCTURE TO RESTRUCTURE THE CORPORATE THE CORPORATE CULTURE CULTURE THROUGH THROUGH BEHAVIORIAL BEHAVIORIAL CHANGES AND CHANGES AND EQUIPMENT EQUIPMENT IMPROVEMENTSIMPROVEMENTS

DEFINITIONDEFINITION A SET OF ACTIVITIES A SET OF ACTIVITIES

FOR RESTORING FOR RESTORING EQUIPMENT TO ITS EQUIPMENT TO ITS OPTIMAL CONDITION OPTIMAL CONDITION AND CHANGING THE AND CHANGING THE WORK WORK ENVIRONMENT TO ENVIRONMENT TO MAINTAIN THOSE MAINTAIN THOSE CONDITIONS CONDITIONS THROUGH DAILY THROUGH DAILY MAINTENANCE MAINTENANCE ACTIVITIESACTIVITIES

PURPOSEPURPOSE

TO IDENTIFY TO IDENTIFY PRODUCTIVITY PRODUCTIVITY LOSSES AND LOSSES AND INVOLVE ALL INVOLVE ALL MEMBERS OF MEMBERS OF THE COMPANY THE COMPANY IN LOSS IN LOSS ELIMINATION ELIMINATION PROGRAMSPROGRAMS

CONTENTS

WHAT IS TPM

BENEFITS OF TPM

PILLARS OF TPM

OPERATOR AUTONOMOUS MAINTENANCE

T- TOTAL

P-PRODUCTIVE

M-MAINTENANCE

MEANING OF TPM•TOTAL EFFICENCY MAXIMISATION

•TOTAL LIFE CYCLE OF PRODUCTION SYSTEM

•TOTAL MANPOWER COVERAGE

PRODUCTIVITY MAXIMISATION BY:

•ZERO ACCIDENT

•ZERO DEFECT

•ZERO BREAK DOWN

MAINTENANCE COVERS LIFE CYCLE OF PRODUCTION SYSTEM:

•INDIVIDUAL PROCESSES

•PLANTS

•PROD.MGT.SYSTEM

Breakdown Preventive Corrective Maintenance Maintenance Maintenance Maintenance Prevention <1950 1950-1970 1957-1978 1960-1980

A BRIEF HISTORYTotal Productive Maintenance 1971-Present

WHAT ARE THE BENEFITS?

•Increased productivity

•Improved quality

•Improved skills

•Safe work environment

•Job security

PILLARS OF TPMPILLARS OF TPMFo

cuss

edIm

prov

emen

t

Aut

onom

ous

Mai

nten

ance

Plan

ned

Mai

nten

ance

Educ

atio

n &

Trai

ning

Early

Equ

ipm

ent

Man

agem

ent

8 Pillars of TPM

(1989 – Present)

Qua

lity

Mai

nten

ance

Indi

rect

Dep

artm

ent

Safe

ty &

Env

iron.

Man

agem

ent

Focused Focused ImprovementImprovement

In this Operators And Technical Services Group aim to

•Focus on specific losses and increase productivity

•Ensure adequate methods for identification of losses and countermeasure implementation

•Increase ease of detecting /correcting deterioration of equipment.

Seven Big Seven Big LossesLosses

Brea

kdow

n

Defe

cts

Min

or S

topp

ages

C/O

ver &

Adj

Tool

Cha

nge

Red

uced

Spe

ed

Star

t-up

Loss ---

------

--- C

umul

ative

% --

------

------

100 %

0 %

FOCUS AREAS IN FOCUS AREAS IN FOCUSSEDFOCUSSED

IMPROVEMENTIMPROVEMENT MINIMIZE BREAKDOWN LOSSESMINIMIZE BREAKDOWN LOSSES ELIMINATE MINOR STOPPAGE LOSSELIMINATE MINOR STOPPAGE LOSS ELIMINATE CHANGE OVER LOSSELIMINATE CHANGE OVER LOSS MINIMIZE SET-UP LOSSMINIMIZE SET-UP LOSS

What Is Autonomous What Is Autonomous Maintenance?Maintenance?

Activities in which each operator performs cleaning,timely inspection,lubrication and consumable parts replacement on their own equipment.

Initial Clean-up

T P M

Countermeasures for Hard-To-Access & Source Of Contamination

Prepare Temporary Standards

General Inspection

Autonomous Inspection

Standardization

AutonomousMaintenance

1

5

4

3

6

7

2

Autonomous Maintenance 7 Steps

What Is The Goal Of Operator Autonomous

Maintenance?

Keeping one's own equipment in good

condition by oneself.

Activities Performed By The Operators

Prevent Deterioration

Measure Deterioration

Restore Deterioration

PreventMachine

FromDeteriorating

ImproveWeak

Points InDesign

EstablishBasic

Conditions

KeepOperationConditions

Operators Maintenance

Management

TPM Roles Of

ImproveSkill

What Is Planned What Is Planned MaintenanceMaintenance??

Activities in which operators and maintenance men eliminate losses by daily maintenance,control for replacement of parts,why - why analysis of failures, lubrication control and prevention of repeated breakdowns .

PILLARPILLARPLANNED MAINTENANCEPLANNED MAINTENANCE

AIM: AIM: REALISE EFFICIENCY IN REALISE EFFICIENCY IN MAINTENANCE DEPARTMENT TO MAINTENANCE DEPARTMENT TO ELIMINATE 8 MAJOR LOSSESELIMINATE 8 MAJOR LOSSES

METHOD: METHOD: DAILY MAINT., TBM, CBM, DAILY MAINT., TBM, CBM, IMPROVEMENT FOR INCREASING THE IMPROVEMENT FOR INCREASING THE SERVICE LIFE EXPECTANCY, CONTROL SERVICE LIFE EXPECTANCY, CONTROL FOR REPLACEMENT, CONTROL FOR FOR REPLACEMENT, CONTROL FOR REPLACEMENT OF PARTS,FAILURE REPLACEMENT OF PARTS,FAILURE ANALYSIS AND PREVENTION OF RE-ANALYSIS AND PREVENTION OF RE-OCCURRENCE,LUBRICATION CONTROLOCCURRENCE,LUBRICATION CONTROL

Analysis-Basic and usage condition:present state selection of priority parts

T P M

Improvement-difference basic and usage condition:present state?present mtn method

Prepare standards:basic and usage conditions

Extension of service life

Improvement:inspection And mtn efficiency

Overall equipment diagnosis

1

5

4

3

6

7

2

Use eqp to limits

7 STEPS OF PLANNED MAINTENANCE

PLANNED PLANNED MAINTENANCEMAINTENANCE

OPERATOR AND OPERATOR AND MAINTENANCE MAINTENANCE

MENMEN

WHO?

ACTIVITIES FOR ACTIVITIES FOR PLANNED PLANNED

MAINTENANCEMAINTENANCE

REDUCTION IN VARIATION OF REDUCTION IN VARIATION OF BREAKDOWN FREQUENCYBREAKDOWN FREQUENCY

EXTENSION OF LIFE SPANEXTENSION OF LIFE SPAN ESTABLISHED TIME BASED ESTABLISHED TIME BASED

MAINTENANCEMAINTENANCE PREDICTION OF FAILURESPREDICTION OF FAILURES

REDUCTION IN VARIATION REDUCTION IN VARIATION OF BREAKDOWN OF BREAKDOWN

FREQUENCYFREQUENCY

HANDLING HANDLING LATENT LATENT DEFECTSDEFECTS

ESTABLISH ESTABLISH BASIC BASIC CONDITIONSCONDITIONS

EXTENSION OF LIFE EXTENSION OF LIFE SPANSPAN

IMPROVE IMPROVE DESIGN WEAK DESIGN WEAK POINTSPOINTS

ELIMINATE ELIMINATE INCIDENTAL INCIDENTAL FAILURESFAILURES

RESTORE RESTORE EXTERNAL EXTERNAL DETERIORATIONDETERIORATION

ESTABLISHED TIME ESTABLISHED TIME BASED MAINTENANCEBASED MAINTENANCE

TIME BASED TIME BASED RESTORATION RESTORATION OF OF DETERIORATIONDETERIORATION

DETECTION OF DETECTION OF SIGN OF SIGN OF ABNORMALITY ABNORMALITY INSIDE INSIDE EQUIPMENT EQUIPMENT THROUGH THROUGH SENSESSENSES

PREDICTION OF PREDICTION OF FAILURESFAILURES

PREDICTION OF PREDICTION OF SERVICES LIFE SERVICES LIFE THROUGH THROUGH EQUIPMENT EQUIPMENT DIAGNOSIS DIAGNOSIS TECHNIQUETECHNIQUE

TECHNOLOGICATECHNOLOGICAL ANALYSIS OF L ANALYSIS OF CATASTROPHIC CATASTROPHIC FAILUREFAILURE

TPM MEASUREMENTSTPM MEASUREMENTS

CHANGE OVER CHANGE OVER TIMETIME

EQUIPMENT CHECK EQUIPMENT CHECK TIMETIME

CLEAN-UP TIMECLEAN-UP TIME MINOR MINOR

STOPPAGESSTOPPAGES MAINTENANCE MAINTENANCE

COSTSCOSTS ACCIDENTSACCIDENTS

DOWNTIMEDOWNTIME 1.PLANNED1.PLANNED 2.UNPLANNED2.UNPLANNED # OF # OF

EQUIPMENTS EQUIPMENTS FAILURESFAILURES

DEFECT RATEDEFECT RATE

Equipment Failure Statistic12%

Of Equipment Failures Are Due To Dirt And Poor Clean-Up Habits

Other Equip. Failures

51%

Dirt12%

Lubrication Method13%

Lack Of Lubricant

24%

Source: JIPM

PILLARPILLAREDUCATION AND EDUCATION AND

TRAININGTRAINING AIM:AIM:RAISE THE TECHNICAL SKILL RAISE THE TECHNICAL SKILL

LEVEL OF OPERATORS AND LEVEL OF OPERATORS AND MAINTENANCE MENMAINTENANCE MEN

METHODMETHOD::BASIC MAINTENANCE BASIC MAINTENANCE STEPS-NUTS &BOLTS- KEY MATING-STEPS-NUTS &BOLTS- KEY MATING-BEARINGS-GEAR TRANSMISSION-BEARINGS-GEAR TRANSMISSION-LEAKAGE PREVENTION-HYD LEAKAGE PREVENTION-HYD &PNEUMATIC EQPT-ELECTRICAL &PNEUMATIC EQPT-ELECTRICAL CONTROL SYSTEMS CONTROL SYSTEMS

EDUCATION &TRAININGEDUCATION &TRAINING

WHO?WHO?

OPERATORS OPERATORS &MAINTENANCE &MAINTENANCE

MENMEN

ANY QUERIES ?ANY QUERIES ?

THANKSTHANKS