Total Productive Maintenance (TPM)

Hi readers ! today we will learn about Total Productive Maintenance(TPM).

Policy and objectives

• To maximize overall equipment effectiveness (Zero breakdowns and failures, Zero accident, Zero defects etc) through total employee involvement.
• To improve equipment reliability and maintainability to contribute to quality and to raise productivity.

What is TPM?

• Total Productive Maintenance (TPM) is both
  • a philosophy to penetrate throughout an operating company touching people of all levels
  • a collection of techniques and practices aimed at maximizing the effectiveness (best possible return) of business facilities and processes

It is a Japanese approach for

• Creating company culture for maximum efficiency
• Striving to prevent losses with minimum cost
  • Zero breakdowns and failures, Zero accident, Zero defects etc
• The essence of teamwork (small group activities) focused on condition and performance of facilities to achieve zero loss for improvement
• Involvement of all people from top management to operator

History/Origin

• TPM was first introduced in Japan 40 years ago and rigorously applied in past 20 years
• TPM planning & implementation in Japanese factories was supported by JIPM (Japan Institute of Plant Maintenance)
• Awarded yearly prizes to various industries:
  • Automotive
  • Metals
  • Chemicals
  • Rubber
  • Food
  • Glass etc.

Traditional Maintenance	TPM
Reactive maintenance is inherently wasteful and ineffective with following disadvantages: * No warning of failure * Chances of safety risk * Unscheduled downtime of machinery * Production loss or delay * Possible secondary damage	* Real cost of reactive maintenance is more than the cost of maintenance resources and spare part * Pro-active maintenance (planned, preventive and predictive) more desirable than reactive maintenance
Requirements in traditional maintenance Need for: * Stand-by machinery * A stand-by maintenance team *A stock of spare parts Costs include: * Post production * Disrupted schedule * Repair cost * Spare parts	TPM provides TPM enables or provides: * The traditional maintenance practices to change from reactive to pro-active * A number of mechanisms whereby * Breakdowns are analyzed * Causes investigated *Actions taken to prevent further breakdowns * Preventive maintenance schedule to be made more meaningful * To ‘free up’ maintenance professionals to: * Carry out scheduled and preventive maintenance *Gather relevant information as important input to the maintenance system *Keep the system up to date *To review cost effectiveness *To develop and operate a very effective maintenance system an integral part of manufacturing

Why is TPM so popular and important?

Three main reasons:

1. It guarantees dramatic results (Significant tangible results) 

•       Reduces equipment breakdowns

•       Minimizes idle time and minor stops

•       Less quality defects and claims

•       Increases productivity

•       Reduces manpower and cost

•       Lower inventory

•       Reduces accidents

2. Visibly transform the workplace  (plant environment) 

•       Through TPM, a filthy, rusty plant covered in oil and grease, leaking fluids and spilt powders   can be reborn as a pleasant and safe working environment

•       Customers and other visitors are impressed by the change

•       Confidence on plant’s product increases

3. Raises the level of workers knowledge and skills As TPM activities begin to yield above concrete results, it helps: 

•       The workers to get motivated

•       Involvement of the workers increases

•       Improvement suggestions multiply

•       People begin to think of TPM as part of the job