Total Preventive Maintenance
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Transcript of Total Preventive Maintenance
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