SCM AND TPM

DHANYA.MRoll No: 07

MBA-IB

What is TPM?Textbook Definition is;

“TPM is a plant improvement methodology which enables continuous and rapid improvement through use of employee involvement, employee empowerment, and closed-loop measurement of results.”

A complete definition of TPM includes the following five elements:

1. TPM aims to maximize equipment effectiveness.

2. TPM establishes a thorough system of PM for the equipment’s entire life span.

3. TPM is implemented by various departments (engineering, operations, maintenance etc).

4. TPM involves every single employee, from top management to workers on the floor.

5. TPM is based on the promotion of PM through motivation management: autonomous small group activities.

JMAC

Sanitation Supv

UC Supv.

Main. Mgr.

Seattle Supv.1st Shift Oper

TPM Coordinator

2st Shift Oper

QA. Mgr.

2st Shift Oper

1st Shift SupvVP of Mftg.

Characteristics of TPMOptimum relationships between

people and equipment/processInvolvement of everyone, from

top leadership to shop floor workers

A cross-functional approach, involving all departments

Implementation through small group teamwork

TPM Goals

Zero Accidents

Zero unplanned downtime

Minimum life cycle

Zero unplanned down time cost

Zero defects

Zero waste!

Results of implementing TPM

Overall Equipment Effectiveness (OEE) Improved

Mean Time Between Failure Improved

Mean Time To Repair Improved

Types of Maintenance

“Means the act of maintaining, To keep in a state of order”

That is, to keep in due (rightful, proper, fitting) condition, operation, or force; keep unimpaired.

Types of Maintenance1. Breakdown maintenance: It

means that people waits until equipment fails and repair it.

2. Preventive maintenance: It is a daily maintenance design to retain the healthy condition of equipment and prevent failure

2a. Periodic maintenance (Time based maintenance - TBM) :

2b. Predictive maintenance

Types of Maintenance3. Corrective maintenance (1957)

: It improves equipment and its components so that preventive maintenance can be carried out reliably.

4. Maintenance prevention (1960): It indicates the design of new equipment.

SIMILARITIES BETWEEN TQM AND TPM: The TPM program closely resembles

the popular Total Quality Management (TQM) program.

Total commitment to the program by upper level management is required in both programmes

Employees must be empowered to initiate corrective action, and

A long range outlook must be accepted as TPM may take a year or more to implement and is an on-going process.

TPM Is a Paradigm ShiftOld Attitude“I operate, you fix”“I fix, you design”“I design, youoperate”

”TPM Attitude“We are all responsiblefor our equipment,our plant, andour future

Pillars of TPM

Pillar- 1 5S1. Sort: Separate out all that is unnecessary and eliminate

it.

2. Store: Put essential things in order so they can be easily accessed. Everything has a place… and is in its place. And visual management.

3. Shine: Clean everything – tools and workplaces – removing stains, spots, debris and eradicating sources of dirt. Bring everything to “NEW” and better than new.

4. Standardize: Standardize the previous three steps to make the process one that never ends and can be improved upon.

5. Sustain: Make cleaning and checking routine.

PILLAR 2 - Autonomous maintenance

SHARED RESPONSIBILITY OF MAINTAINING  ”BASIC CONDITIONS”

OF EQUIPMENT BETWEEN PRODUCTION AND MAINTENANCE.

PILLAR 2 - Autonomous maintenanceKey Concepts

Shop floor based activities Operator conducted Operator enhancing Team activity Autonomous Management TPM Foundation Part of the job!

Key Concepts

Shop floor based activities Operator conducted Operator enhancing Team activity Autonomous Management TPM Foundation Part of the job!

3 Key Tools Activity Board

Meetings

One Point Lessons

3 Key Tools Activity Board

Meetings

One Point Lessons

The 7 steps of Autonomous Maintenance1. Initial Cleaning (Initial Inspection &

“Restoration”)

2. Source of Contamination & Hard-to-Reach areas

3. Standards of Cleaning & Lubrication

4. General Inspection

5. Autonomous Inspection

6. Standardize Autonomous Maintenance operations

7. Autonomous Management

Autonomous Maintenance

Before After

PILLAR 3 - Process Improvement And Overall Equipment Effectiveness:

Objectives Maximizing the performance of equipment by

minimizing losses of equipment

Problem Solving by GROUPS

Objectives Maximizing the performance of equipment by

minimizing losses of equipment

Problem Solving by GROUPS

• Compare the ACTUAL operating time versus the OPTIMUM operating time

• Highlight the causes of Productivity losses :• Availability, Performance and Quality losses

PILLAR 3 - Process Improvement And

Overall Equipment Effectiveness:Policy to be followed:Practice concepts of zero losses in

every sphere of activity.relentless pursuit to achieve cost

reduction targets in all resourcesRelentless pursuit to improve over all

plant equipment effectiveness.Extensive use of PM analysis as a tool

for eliminating losses.Focus of easy handling of operators

PILLAR-3- OEE

Improvement Steps

Define Losses Quantify

LossesAnalyze Causes

Generate Counter-measures

Implementation

Follow up

PILLAR 4 - Planned Maintenance

Objectives: Increase Equipment Reliability and Production

Up-TimeMinimize the maintenance cost by 1) reducing breakdowns 2) development of efficient maintenance

methods

Objectives: Increase Equipment Reliability and Production

Up-TimeMinimize the maintenance cost by 1) reducing breakdowns 2) development of efficient maintenance

methods

Planned Maintenance – 6 Steps

Step 1: Evaluate Equipment and Understand Current Conditions

Step 2: Restore Deterioration and Correct Weaknesses

Step 3: Build an Information Management System

Step 4: Build a Periodic Maintenance System

Step 5: Build a Predictive Maintenance System

Step 6: Evaluate the Planned Maintenance System

Planned Maintenance- Policy

Achieve and sustain availability of machines

Optimum maintenance cost.Reduces spares inventory.Improve reliability and

maintainability of machines.

PILLAR 5 - Quality Maintenance:Aim To ensure that a plant is in a

perfect condition – where 100 % quality goods are produced, zero defects

Aim To ensure that a plant is in a

perfect condition – where 100 % quality goods are produced, zero defects

Result Oriented Approach

“after it has happened”

Result Oriented Approach

“after it has happened”

Cause Oriented Approach“before it happens”

Cause Oriented Approach“before it happens”

Quality Maintenance:Steps:Establish conditions for “zero defects”Prevent the occurrence of quality

defects by maintaining the conditions within certain standardsInspect and monitor such conditions

in time seriesPredicting the possibility of quality

defect occurrence by reviewing changes in measured valuesTake countermeasures in advance

PILLAR 6 - TRAINING

Objectives 1) Enhance employees’ ability

and skill in TPM methods 2) Provide necessary TPM

methodology at the right time 3) Provide challenge targets for

individuals by clarifying the hierarchy of skills

Objectives 1) Enhance employees’ ability

and skill in TPM methods 2) Provide necessary TPM

methodology at the right time 3) Provide challenge targets for

individuals by clarifying the hierarchy of skills

PILLAR 6 - TRAININGStep 1: Skills/Techniques Inventory and

HierarchyCreate a list of Operational and

Maintenance Skills and TechniquesStep 2: Design Training System

Including follow-up system such as OJT (on the job training)

Documentation of Individual Skill LevelsStep 3: Set Individual Skill Challenge Target Step 4: Training and Evaluation

Pillar VII : Administrative Work Improvement

Objectives 1) Minimize losses 2) Improve quality of work 3) Clear work allocation

Objectives 1) Minimize losses 2) Improve quality of work 3) Clear work allocation

Pillar VII : Administrative Work Improvement

Design Approach

Engineering Approach

Customer Expectations

Customer Expectations

Organizational Mission

Organizational Mission

Departmental Mission

Departmental Mission

Individual

Roles &

Responsibilities

Individual

Roles &

Responsibilities

Make a List of all the work in the office

Clarify priorities of all the work in the office

Step 1 Step 1 Work Inventory

Work Inventory

Step 2 Step 2 Priority Analysis

Priority Analysis

Step 3 Step 3 Work Allocation

Analysis

Work Allocation

Analysis

Step 4 Step 4 Activity Analysis

Activity Analysis

Clarify work allocation of all the work

Capture the trend and benchmark of

Office work utilization

Step 5 Step 5 Information Flow

Analysis

Information Flow

Analysis

Step 6 Step 6 Document Analysis

Document Analysis

Step 7 Step 7 Meeting Analysis

Meeting Analysis

Clarify detailed process flow of information

Clarify objectives and design of documents

Clarify objectives and design of meetings

Environment Management

PILLAR 8 - SAFETY, HEALTH AND ENVIRONMENT:Target = “Maintenance of peace of mind

“ Target = “Maintenance of peace of mind

“

Safety Management

Zero AccidentZero Injury

Zero PollutionZero Waste

CONCLUSION: Today, with competition in industry at an all

time high, 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. Employees must be educated and convinced that TPM is not just another "program of the month" and that management is totally committed to the program and the extended time frame necessary for full implementation

THANK YOU