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Goudar Associates
TPM stands for - - Total Profit Management Through Total Perfect Manufacturing Through
Developed from the US style of PM (preventive maintenance) in 1950s Subsequently, developed to its present state by JIPM (Japan Institute of Plant Maintenance) Now, TPM promotes entire company structures, every line of businesses, and in all parts of the world TPM is implemented company wide
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Key-words
Breakdown maintenance
Explanation
Repairing after failure by the person in charge of repairs Management of equipment is not considered Preventive maintenance of equipment by the person in charge of maintenance Economical maintenance control Management of total equipment life (equipment planning, maintenance, improvement, revision) by the person in charge of equipment from the economical point of view Production maintenance by all members related to equipment planning, operation and maintenance TPM activity by all members related to production, development, business, and management, etc. Global and general TPM activity including local production
1950s
Preventive maintenance
1960s
Productive maintenance
1970s
TPM in production department (Manufacturing industry) Company wide TPM (whole industry) Global TPM
1980s
1990s 2000s
TPM development in unmanned operation plants TPM in unmanned operation by employing FA/CIM plants Goudar Associates 4
TPM Features
Daily Preventio n
Early treatment
Inspection (diagnosis)
Preventive Maintenance
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BENEFITS OF TPM
(Effectiveness)
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Tangible Effectiveness
Productivity
Quality
Cost Inventory Accident Morale
(Dispatch Adherence
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C
D S M
production system
3. TPM is applied in all sectors, including the production, development, sales and administration departments 4. TPM is based on the participation of all members, ranging from the top management to frontline employees 5. TPM achieves zero losses through overlapping small-group activities
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From TPM of Production Department of Company-wide TPM Covering All Company Activities
Top Management
Planning
Financial
Personnel
General Affairs
Administration
Production
Sales
Plant
Plant
Plant
TPM of Production Department Company-wide TPM encompassing production, development, sales and administration
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human
resources
(1) Attain efficiency through revamping of the existing equipment (2) LCC-considered design of new equipment and minimizing their run-up time
GOALS OF TPM
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TPM
Education & Training
TPM 8 PRINCIPLES
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Shutdown loss
Time lost when production stops for planned annual shutdown maintenance or periodic servicing
Time lost when changes in supply & demand require adjustments to production plans Time lost when equipment suddenly loses its specified functions Time lost in shutdown due to external factors such as changes in chemical or physical properties of materials being processed, operating errors, defective raw materials, etc.
Days
Shutdown work, periodic servicing, statutory inspections, autonomous inspections, general repair work, etc.
Production-adjustment shutdown, inventory-reduction shutdown, etc. Failed pumps, burnt-out motors, damaged bearings, broken shafts, etc. Leaks, spills, blocks, corrosion, erosion, dust scatter, misoperation
Days
Hours
Hours
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Rate loss occurring when plant underperforms due to malfunctions & abnormalities Time lost due to producing rejectable product, physical loss of rejected product, and financial losses due to product downgrading Recycling losses due to passing material back through the process
Reprocessing loss*
Recycling losses occur when rejected material has to be returned to a previous process to make it acceptable 20
* In certain industries or with certain products, reprocessing or reworking is impossible. In such cases, these types of losses will be treated as quality losses & accordingly, eight major losses are reduced to seven.
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OFFICE TPM
LOSS
PLANNED MAINTENANCE
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Plant
C A
100
(%)
100
Operating time (C) Net Operating Time (D) Effective Performance losses
=
Quality rate =
D C
100
(%)
Production amount
(7+8)
Production amount
100
=
Availability
E D
100
(%)
Performance rate
Quality rate
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TPM
DEPLOYMENT
IN 12 STEPS
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TPM
Education & Training
TPM 8 PRINCIPLES
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