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T O TA L P R O D U C T I V E M A I N T E N A N C E

A P P L I C AT I O N S I N

SMEs
R E P O RT

By: IJAZ-UL-HASAN

N AT I ON A L P R O D U C T I V I T Y OR GA N I S AT I O N
MINISTRY OF INDUSTRIES & PRODUCTION,
G O V E R N M E N T O F PA K I S TA N
Contents
Contents..................................................................................................................... 2

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Key Learning from the Training Course
TOTAL PRODUCTIVE MAINTENANCE

TPM is a culture that focuses on improving the effectiveness of the plant, equipment and
processes through the empowerment of PEOPLE. To Implement TPM commitment of Top
Management is utmost important.

• TPM

– T stands for “Total”

– P stands for “Productive”

– M stands for “Maintenance”

• Total means that all workers of a corporation are required to participate in this activity.

TPM Literature Review


8 pillars in TPM

1. Autonomous maintenance

2. Focused improvement

3. Planned maintenance

4. Education and training

5. Initial management

6. Quality maintenance

7. Office TPM

8. Safety and environment

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Autonomous maintenance

This pillar is geared towards developing operators to be able to take care of small maintenance
tasks, thus freeing up the skilled maintenance people to spend time on more value added activity
and technical repairs. The operators are responsible for up keep of their equipment to prevent it
from deteriorating.

Planned Maintenance
The goal of planned maintenance is to have trouble-free machines and equipment that produce
defect-free products for total customer satisfaction. Planned Maintenance achieves and sustains
availability of machines at an optimum maintenance cost, reduces spares inventory, and
improves reliability and maintainability of machines.

With Planned Maintenance the associates’ efforts evolve from a reactive approach to a proactive
method and trained maintenance staff helps train the operators to better maintain their equipment

Education & Training pillar

The goal of training is to have multi-skilled employees whose morale is high and who are eager
to come to work and perform all required functions effectively and independently.

The focus is on achieving and sustaining zero losses due to lack of knowledge / skills /
techniques. Ideally, we would create a factory full of experts.

It is not sufficient for operators to learn how to do something; they should also learn why they
are doing it and when it should be done. Through experience operators gain “know-how” to
address a specific problem, but they do so without knowing the root cause of the problem and
when and why they should be doing it. Hence it becomes necessary to train operators on
knowing why.

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Quality Maintenance

Quality Maintenance (QM) targets customer satisfaction through defect free manufacturing of
the highest quality products. The focus is on eliminating non-conformances in a systematic
manner. Through QM we gain an understanding of what parts of the equipment affect product
quality, eliminate quality concerns, and then move to potential quality concerns. The transition is
from reactive to proactive (From Quality Control to Quality Assurance).

QM activities control equipment conditions to prevent quality defects, based on the concept of
maintaining perfect equipment to maintain perfect quality of products.

Office TPM

Office TPM should be started after activating four other pillars of TPM (Jishu Hozen, Kobetsu
Kaizen, Quality Maintenance, and Planned Maintenance).

Office TPM must be followed to improve productivity, efficiency in the administrative functions,
and identify and eliminate losses. This includes analyzing processes and procedures towards
increased office automation.

Safety, Health and Environment Pillar

The focus is on creating a safe workplace and surrounding areas that are not damaged by our
process or procedures. The target of the Safety, Health & Environment pillar is:

• Zero accidents

• Zero health damage

• Zero fires

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12 steps of TPM Implementation
1. Declaration of resolve to introduce TPM by top management

2. TPM introduction education and campaign

3. TPM promotion organization and manager pilot model

4. Setting basic policy and target for TPM

5. Preparation of TPM master plan

6. Kick off

7. Establish of production efficiency improvement system

8. Establish of initial management system

9. Establish of quality maintenance system

10. Establish of office TPM

11. Establish of safety and environment system

12. Evaluation (TPM excellence award)

TPM Tools and Other Key Terms


Overall Equipment Effectiveness (OEE)

OEE = Availability X Performance rate X Quality products rate

Availability = Loading time – Downtime losses x 100

Loading time

Performance = Cycle Time x Processing quantity x 100

Operating time

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Quality Product rate = Processing quantity – Defective quantity x 100

Processing quantity

Mean Time Between Failure (MTBF)

An average time between a machine failure and the next failure. It is calculated by dividing
total operating time by the number of failures

Mean Time To Repair (MTTR)

An average of the time needed for repairing a machine

One Point Lesson

A TPM 1-point lesson is just one of the many tools that can be used to improve knowledge and
understanding of the condition and performance of an asset/machine on a day-to-day basis.

The approach engages the front-line operations and technicians and encourages them to get
involved in the continuous improvement of the asset/machine. By simply passing on good ideas,
maintenance interventions can be optimized to ensure their maximum impact on either the
performance or condition of the assets/machine.

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Objectives for TPM implementation in SMEs
• To promote TPM among SMEs as a tools for striving toward cost saving strategy and an
activity for improvement, problem solving and preventive action on protecting the
increase in number of machine breakdown;

• To create awareness, training, managing consulting for SMEs in applying TPM;

• To create guideline and simplified the process as a guidance in implementing TPM


among SMEs;

• To ensure the incremental of the profit gain by SMEs through the effectives of TPM
implementation; and

• To Increase the number of knowledge and skill workers especially among SMEs in order
to contribute for government incomes.

Goals of TPM
• Zero Breakdown

• Zero Accidents

• Zero Wastages

Objectives of TPM

• Reduce Cost

• To Increase Equipment effectiveness (OEE)

TPM Implementation Steps in SMEs for Pakistan Industry

• Steps to Implement TPM

– 3 ‘S’ / Workplace Management / Housekeeping

– Education & Training

– Autonomous (Cleaning – Inspection – Lubrication)

– Planned Maintenance

– Quality Maintenance

– Safety and Environment

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Action Plan for TPM implementation in SMEs
Proposed Month
S.No Activity
Duration 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
1 3 'S' Implementation 4 months
TPM Awareness
2
Program 2 months
Data Collection &
analysis / Presenting
3 2 months
current situation and
Master plan for future
5 Establish TPM pillars 12 months
6 Education and Training 2 months
7 Audit 2 month

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