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
