Pillars of TPM

Pillars of TPM

•  Autonomous maintenance, 
• Planned Maintenance, 
• Equipment  and process improvement, 
• Early management of new equipment , 
• Process quality management, 
• TPM in office, 
• Education and training, 
• Safety & environment Management

Overview of 8 pillars

1st  Pillar - Autonomous maintenance

 Objective

• To develop self-management activities through small groups.
• To develop the skills of operators and a desire to "protect their equipment by themselves / themselves"

Activities

• Create awareness of forced deterioration, identify and correct abnormalities.
• Develop standards for basic maintenance and maintain basic conditions.
• To develop equipment consciousness through machine and systems education.
• Standardize operations and prevent deterioration.

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Types of deterioration

• Natural deterioration :- Ageing under Standard Operating Conditions
• Forced deterioration :- Artificially Accelerated because of Non-Standard Operating Conditions

2nd Pillar - Planned maintenance 

Aim   : Realise efficiency in maintenance department to eliminate all losses 

Method: Daily maintenance

 TBM, CBM, Improvement for increasing the service  life expectancy, control for replacement of parts, failure analysis and prevention of re-occurrence, Lubrication control  

Who :- Operator and maintenance men 

3rd Pillar -  Equipment & Process Improvement 

Aim   : 

• To focus on specific losses & Increase productivity, ease of operation & Standardization of methods

• To ensure adequate methods for identification of losses & countermeasure implementation

• To increase ease of detecting / correcting deterioration of equipment

Method: Repeated Equipment Breakdown Analysis & Countermeasures, CAPA-Do for Minor Stoppages, CAPA-Do for Change-over, CAPA-Do for Defects 

Who: Operator and Technical Services Group

4th  Pillar – Early Management of New Equipment.  

Aim   : Shorten the trial period for new product, design of new equipment, and runup time for stable launching of products.

Method: 

• Easy to maintain and reliable equipment.

• Review of design methodologies.

Who : R & D / Production Engg Staff . 

5th Pillar -  Process Quality Management.  

Aim   : Realise ‘Zero’ defects through observing the required  equipment maintenance

Method: Distortion and defect characterization of standards for quality characteristics and identifying actual defect records.  Ensure product quality, check status of unit process materials and equipment, and energy use of production methods.  Under such circumstances, observe, analyze and assist.  (QRQC)

Who: Staff and cell line or leaders 

6th  Pillar – TPM in office.  

Aim   : Realise Zero functional loss, Organise high efficiency loss, Render service and support function to the service departments   

Method: By 5 pillar activities

Who : Members of sales and administrative  & finance departments

  7th Pillar – Education and Training.  

Aim   : Raise the technical skill level of operators and maintenance men 

Method: Basic maintenance steps- nuts & bolts - key mating - Bearings- Gear Transmission- Leakage prevention- Hydraulics & Pneumatic equipment - Electrical control systems 

Who    : Operators and maintenance

8th pillar- Safety and Environment Management

Aim   : Attain and keep the Zero accident level, Create a healthy and clean working area 

Method: Safety measures to protect the operators from equipment accidents, Make the operation safe, Improve the working environment - noise, dust, Measures to achieve environment protection. Attention to the health and hygiene of the employees promotion of cheerful working environment. 

Who:  Managers  & staff 

TPM

 TPM DEFINITION

• TPM is a productive maintenance involving total participation.
• TPM  is a productive maintenance implemented by all employees in an organization.
• TPM covers everyone from operators to senior management in equipment improvementTPM is a productive maintenance implemented by all employees in an organization.

TPM IN THREE WORD

T- TOTAL - All individual in an organization Working together

P- PRODUCTIVE - Production of goods that meet or exceed customer's expectation

M- MAINTENANCE - keeping equipment and plant in good condition all time

HISTORY OF TPM

• It is an innovative Japanese concept.
• Developed in 1951.
• Nippondenso was the first company to implement TPM in 1960.
• Based on these developments, Nippondenso was awarded the prestigious Plant Award by the Japanese Institute of Plant Engineers (JIPE) for developing and implementing TPM.
• Nippondenso becomes 1 company to obtain TPM certificate

GOALS OF TPM

• Increase in production quality.
• Increase job satisfaction.
• Using teams for continuous improvement.
• Improvement in maintenance conditions.
• Empower employees.

WHY TPM

• Avoid wastage in a rapidly changing economic environment.
• Reduce the cost of production.
• Produce lower batch quantities in the initial time.
• Goods shipped to customer must be non-defective

Within TPM there are five developmental activities

1. Use small group activities to improve equipment effectiveness by eliminating major equipment related losses.
2.  Involve operators in daily maintenance activities to maintain basic equipment condition (daily cleaning, lubrication, inspection, tightening)
3. Increasing the efficiency and cost effectiveness of maintenance work through better scheduling and management.
4. Training to improve the skills of all involved (operators, maintenance mechanics, supervisors, management etc.).
5. An initial equipment management program to prevent start up and / or ongoing problems with new equipment (adopting a total life cycle cost approach to equipment management)