TPM by Chandan Jha

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WELCOME WELCOME TO THE WORLD OF TO THE WORLD OF TPM TPM TPM TPM 11 Prepared by : Chandan jha
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Transcript of TPM by Chandan Jha

Page 1: TPM by Chandan Jha

WELCOMEWELCOMETO THE WORLD OFTO THE WORLD OF

TPMTPMTPMTPM

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TPMTPM

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ContentsContents--Definition

History and origin,

List of TPM certified company.

Objective

Benefits of TPM

Why TPM,

TPM GoalTPM Goal

TPM Participants

TPM Strategies

Pillars of TPM

Op/Maint partnership

Autonomous maintenance

Slogans

Conclusion3

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DefinitionDefinition

“TPM is a management

process developed for

improving productivity

by making processes

more reliable and

less wasteful.”

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HISTORY AND ORIGIN HISTORY AND ORIGIN

United States

Henry Ford

Preventive

FROM

Japan -

Nippon

Denso

TO

Preventive

Maintenance

Denso

Productive

Maintenance

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HISTORY HISTORY CONT’D…CONT’D…

�Preventive maintenance along with Maintenance prevention and Maintainability Improvement gave birth to Productive maintenance.

�By then Nippon Denso had made quality circles, �By then Nippon Denso had made quality circles, involving the employees participation. Thus all employees took part in implementing Productive maintenance.

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HISTORY HISTORY CONT’D…CONT’D…

�TPM is a innovative Japanese concept which can be traced back to 1951.

�However the concept of preventive maintenance was taken from USA. Nippondenso was the first was taken from USA. Nippondenso was the first company to introduce plant wide preventive maintenance in 1960.

�Nippondenso which already followed preventive maintenance also added Autonomous maintenance done by production operators.

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HISTORY HISTORY CONT’D…CONT’D…

Whereas in most production settings the

operators are not viewed as a member of

the maintenance team, in TPM the the maintenance team, in TPM the

machine operators are trained to perform

many of the day-to-day tasks of simple

maintenance and fault-finding.

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List of TPM certified List of TPM certified

company.company.�Electrosteel Castings Limited

�Exide Industries Limited

� Indian Oil Corporation Limited

�Jamshedpur Utilities and Services Company �Jamshedpur Utilities and Services Company

Limited

�MRF Limited

�Munjal Showa Limited

�National Engineering Industries Limited

�Brakes India Ltd. Pad 9

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List of TPM certified List of TPM certified

CONT’D…CONT’D…�Brakes India Ltd. Foundry Div., Sholinghur

�Galaxy Surfactants Ltd. Taloja and Tarapur

�Hindustan Unilever Ltd. Khamgaon

�Shriram Pistons & Rings Ltd.�Shriram Pistons & Rings Ltd.

�Sundram Fasteners Ltd. Hosur

�Sundram Fasteners Ltd. Pondicherry

�Brakes India Ltd. Nanjangud

�Hindustan Unilever Ltd.Haldia

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OBJECTIVEOBJECTIVETo restructure the corporate culture

through behavioral changes and

equipment improvements.

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Similarities and differences

between TQM and TPM Total commitment to the program by upper level management is required in both programsEmployees must be empowered to initiate corrective

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Employees must be empowered to initiate corrective action.A long range outlook must be accepted as TPM may take a year or more to implement and is an on-going process Changes in employee mind-set toward their job responsibilities must take place as well.

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WHY TPM?WHY TPM?

� Safe Work Environment

� Job Security

� Quality

� Increased Productivity

� Improved Skills13

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WHY TPM?CONT’D…WHY TPM?CONT’D…

�Avoid wastage in a quickly changing economic

environment.

�Produce goods without reducing product

quality.quality.

�Reduce cost.

�Produce a batch quantity at the earliest possible

time.

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WHY TPM?CONT’D…WHY TPM?CONT’D…

�Creating company culture for maximum efficiency.

�Striving to prevent losses with minimum cost

�The essence of team work (small group �The essence of team work (small group activity) focused on condition and performance of facilities to achieve zero loss.

�Goods send to the customers must be non defective.

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GOAL OF TPMGOAL OF TPM

ZeroProduct

Defects

Zero Accidents s

Zero Equipment Failures

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Team of TPMTeam of TPMTPM involves everyone in the

organization from operators to

senior management

In equipment

improvement. It

encompasses all

most all departments. 17

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CONT’D…CONT’D…

The departments including:�Maintenance

�Operations/production

�Tool Room

�Design Engineering �Design Engineering

�Project Engineering

�Construction Engineering

�Inventory and Stores

�Purchase

�Accounting and Finance

,etc

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TPM STRATEGIESTPM STRATEGIES�Conduct more frequent and thorough

inspection and cleaning of machines to discover

minor discrepancies before they become

failures.

�Enhance PMs to correct

minor defects and

prevent failures.

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TPM STRAIT. TPM STRAIT. CONT’D…CONT’D…

Modify Operations to reduce need for maintenance.

Elevate all employees’ knowledge, skill and role in Elevate all employees’ knowledge, skill and role in

improving equipment performance.

– Engineers, Line Leaders, maintenance

technicians, and especially production operators.

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TPM STRAIT. TPM STRAIT. CONT’D…CONT’D…

Only clean machines and equipment

problems visually apparent!!!

Cleaning is Inspection.

TPM

Cleaning is Inspection.

CLEANING IS CHECKING ! CLEANING IS CHECKING !

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TPM STRAIT. TPM STRAIT. CONT’D…CONT’D…

The starting point for

TPM is implementing

routine inspections by

production operators.

“Autonomous maintenance” –Users/operators

perform continuous inspection for minor defects as

well as continuous cleaning, adjustment, and

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TPM STRAIT. TPM STRAIT. CONT’D…CONT’D…

�Outline a detailed master deployment plan.

�Improve the effectiveness of each piece of

equipment and concern person. equipment and concern person.

�Develop an autonomous maintenance program

for operators.

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TPM STRAIT. TPM STRAIT. CONT’D…CONT’D…

�Conduct training to improve operation and

maintenance skills.

�Develop an early equipment management

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�Develop an early equipment management

program.

�Continuous improvement.

�Develop a planned for preventive

maintenance program.

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PILLER OF TPM� Autonomous Maintenance� 5-S� Jishu Hozen � Kaizen� Planned Maintenance � Planned Maintenance � Quality Maintenance � Office TPM � Education & Training � Safety, Health & Environment � Development Management 25

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Autonomous Maintenance

Activities where each

operator performs timely

inspection, lubrication,

consumable parts

T P M

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consumable parts

replacement, repair,

troubleshooting, accuracy

checks, etc, of their own

equipment.

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OIL

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5-SYou can’t see problems clearly when the workplace is in disarrayCleaning and organizing the workplace helps the team to uncover problemsMaking problems visibleis the first step of improvement

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is the first step of improvementClean machines and workplace create pride & Safety

TPM is the only tool to win the race, Keeping 5-S as its base.

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JISHU HOZEN

Policy-�Uninterrupted operation of equipments.� Flexible operators to operate and maintain other equipments.�Eliminating the defects at source through active employee participation.

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active employee participation.�Stepwise implementation of JH activities.

JISHU HOZEN Targets-�Prevent the occurrence of 1A/1B because of JH.�Reduce oil consumption by 50%.�Reduce process time by 50%.�Increase use of JH by 50%.

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JISHU HOZEN CONT’D…CONT’D…

Steps in JISHU HOZEN-

�Preparation of employees.

�Initial cleanup of machines.

�Take counter measures.

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�Take counter measures.

�Fix tentative JH standards.

�General inspection.

�Autonomous inspection.

�Standardization.

�Autonomous management.

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KAIZENKai means change and Zen means goodThe principle behind is a very large number of small improvements are move effective in an organizational environment than a few improvements of large value.

Policy- Practice concepts of zero losses in every activity- To achieve cost reduction targets in all resources

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- To achieve cost reduction targets in all resources- To improve over all plant equipment effectiveness- Focus of easy handling of operators

Target- Achieve and sustain zero loses with respect to minor

stops, measurement and adjustments- It also aims to achieve 30% manufacturing cost

reduction

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PLANNED MAINTENANACE

It is aimed to have trouble free machines and equipments producing defect free products for total customer satisfaction.

Break down into 4 categories.�Preventive Maintenance

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�Preventive Maintenance�Breakdown Maintenance�Corrective Maintenance�Maintenance Prevention

Target�Zero equipment failure and break down.�Improve reliability and maintainability by 50%.

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PMPM--CONT’D…CONT’D…

Reduce maintenance cost by 20%

- Ensure availability of spares all the time

Six steps in planned maintenance

1. Equipment evaluation and recoding present

status

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status

2. Restore deterioration and improve weakness

3. Building up information management

system

4. Prepare time based information system

5. Prepare predictive maintenance

6. Evaluation of planned maintenance

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QUALITY MAINTENANCE

It is aimed towards customer delight through highest quality through defect free manufacturing.

QM activity is to set equipment conditions that preclude quality defects, based on the basic concept of maintaining perfect equipment to maintain perfect quality of products.

Policyo Defect free conditions and control of equipmentso QM activities to support quality assurance

o Focus of prevention of defects at sourceo Focus on poka-yoka (full proof system)

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QMQM--CONT’D…CONT’D…In-line detection and segregation of defects

- Effective implementation of operator

quality assurance

Target- Achieve and sustain customer complaints

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- Achieve and sustain customer complaints

at zero

- Reduce in-process defects by 50%

- Reduce cost of quality by 50%

Quality defects are classified as customer

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QMQM--CONT’D…CONT’D…

Target- Achieve and sustain downtime due to want men at

zero on critical machines.- Achieve and sustain zero losses due to lack of

knowledge/skills/techniques.- Aim at 100% participation in suggestion scheme.

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- Aim at 100% participation in suggestion scheme.

Steps in education and training activities- Setting policies and priorities and checking present

status of education and training- Establish a training system for skill upgrading- Preparation of training calendar- Evaluation of activities and study of future approach

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OFFICE TPMOffice TPM should be started after activating four other pillars of TPM (JH,KK,QM,PM).

Office TPM addresses 12 major losses- Processing loss- Cost loss in areas like accounts, marketing and sales- Communication loss

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- Communication loss- Idle loss- Set-up loss- Accuracy loss- Office equipment breakdown, telephones and fax- Communication channel breakdown- Time spent on retrieval of information- Non availability of correct on line stock status

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OFFICE TPM CONT’D…CONT’D…

Customer complaints due to logistics- Expenses on emergency dispatches/purchases

Benefits- Involvement of all people in support functions for focusing on better plant performance.

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focusing on better plant performance.- Better utilized work area- Reduce repetitive work- Reduce administrative costs- Reduction in number of files- Reduction in office equipment- Reduce customer complaints- Reduce manpower- Clean and pleasant work environment

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Education & TrainingIt is aimed to have multi skilled employees whose morale is high and who has eager to come to work and perform all required functions effectively and independently.

They are trained to achieve 4 phases of skillsPhase 1 : Do not knowPhase 2 : Know the theory but cannot do

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Phase 2 : Know the theory but cannot doPhase 3 : Can do but cannot teachPhase 4 : Can do and also teach

Policy- Focus on improvement of knowledge and skills- Create a training environment for self learning- Training to remove employee fatigue and make

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SAFETY,HEALTH AND ENVIRONMENT

Target- Zero accident- Zero Health damage- Zero fires

It helps to create a safe workplace and a surrounding area that

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It helps to create a safe workplace and a surrounding area that is not damaged by our process or procedures.

It plays an active role in each of the other pillars on a regular basis.

To create awareness among employees various competitions like safety slogans ,posters etc can be organized at regular intervals.

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OMP - OPERATOR

MAINTENANCE PARTNERSHIP

�Operator training in TPM

�Operator basic equip inspection & tooling checks

TPM

inspection & tooling checks

�Operator basic cleaning

�Operator lubrication check

�One point lessons (capture knowledge)

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CONT’D…CONT’D…

The Ethics of operator is to operate the equipment with high skills level,

The Ethics of Maintenance team is to high skills level,

in order to reduce the down time.

e team is to upgrade the equipment to perform it better.

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CONT’D…CONT’D…

Mother and baby

Operator and Equipment

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SEE THE BELOW

IMAGES…..

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WHAT WAS

COMMON

IN ABOVE IMAGES ?

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LACK OF KNOWLEDGE ?LACK OF KNOWLEDGE ?

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LACK OF AWARENESS ?LACK OF AWARENESS ?

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LACK OF TRAINING?

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THE ANSWER IS :

“LACK OF OWNERSHIP”“LACK OF OWNERSHIP”

THAT IS ATTITUDE PROBLEM.

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ATTITUDE /

THOUGHTTHOUGHT

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THOUGHT CHANGE

I operate the I operate the

Old concept New concept

I operate the machine and I maintain it.

I operate the machine and some body maintains it.

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SEE THE BELOW IMAGES…..SEE THE BELOW IMAGES…..

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What was common

in above picturesin above pictures

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THE ANSWER IS…

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WHAT IS THE GOAL OF OPERATOR

AUTONOMOUSMAINTENANCE?

“Keeping one's

own equipment own equipment

in good

condition by

oneself ”.

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SLOGANS�TPM In, Losses Out.

�Machine not tight, job not right.

�Organization without TPM; Building without

foundation.

�Farmer is the backbone of a country; TPM is �Farmer is the backbone of a country; TPM is

the backbone of industry.

�Accept TPM with a Positive Attitude

Achieve Success of high Magnitude.

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SLOGANS�TPM is the foundation of factory.

�Invest minutes for TPM; Gain hours for production.

Your future is bright, when the TPM �Your future is bright, when the TPM you practice is right.

�Don’t be a fool, use TPM tool.

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AT LAST

“TPM is a Lean

tool for Quality and tool for Quality and

Productivity”

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CONSLUSIONCONSLUSIONToday, with competition in industry is high.

TPM may be the only tools that stands us

success. It has been proven to be a program

that works.

Employees must be educated and convinced Employees must be educated and convinced

that TPM is not just another "program of

the month" .

If everyone involved in a TPM program, an

unusually high rate of return compared to

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THANK YOU,

I sincerely thank you for your co-operation and

consideration for the growth of TPM.

Presented by:

CHANDAN JHA

[email protected]

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