TPM & It's Pillars

TITLE: TPM AND IT’S 8 PILLARS.
PRESENTED BY:
MANAS S. CHAMPANERKAR.
TYME(C).
232.
DEFINITION OF TPM AND IT’S TYPES:
DEFINITION: Total Preventative Maintenance or TPM is a set of techniques
which ensures that each and every machine in the production process is always
able to perform its required task.
TPM PROCEDURE AND BENEFITS: This is done by placing the emphasis on
production operators being trained to handle routine maintenance on a regular
basis – they feel empowered, with a shared responsibility for the equipment and it
frees up engineers to be available for more specialized tasks.
TYPES OF TOTAL PRODUCTIVE MAINTAINANCE:
 BREAKDOWN MAINTAINANCE.
 PREVENTIVE MAINTAINANCR.
 PREDICTIVE MAINTAINANCE.
 PERIODIC MAINTAINANCE,
 CORRECVTIVE MAINTAINANCE.
REQUIREMENT AND GOALS OF TPM:
THE MAJOR OBJECTIVES OF TPM ARE LISTED BELOW:

 AVOID WASTAGE.
 REDUCE THE COST OF MANUFACTURING.
 AVOID ANY DEFECTS IN MANUFACTURING AND ASSEMBLY AS WELL.
GOALS:
 INCREASE IN PRODUCTION WHILE INCREASING THE WORKER’S MORALE AND
JOB SATISFACTION SIMULTANEOUSLY.
 REDUCE BREAKDOWN AND CORRECTIVE MAINTAINANCE.
TPM TARGETS:
 PRODUCTION.
 COST.
 QUALTIY.
 DELIVERY.
 SAFETY.
 MORALE.
TOTAL PRODUCTIVE MAINTAINANCE
TRIANGLE:
5’s
 5’s IS THE BASE OF TOTAL PRODUCTIVE MAINTAINANCE PILLARS.
 WITHOUT A CLEAN AND ORGANIZED WORKPLACE PRODUCTIVITY IS
NOT POSSIBLE.
WHAT ARE THE 5S’S IN 5’S?
 SEIRI- SORT OUT.
 SEITON- ORGANIZE.
 SEISO- SHINE.
 SEIKETSU- STANDARDIZE.
 SHITSUKE- SELF-DISCIPLINE.
5’s EXPLANATION:
5’s EXAMPLE:
PILLAR #1. AUTONOMOUS MAINTAINANCE(Jishu Hozen)
What Is Autonomous Maintenance?

 Autonomous maintenance is a method in manufacturing that gives machine
operators the responsibility for basic maintenance tasks, rather than relying on
dedicated maintenance technicians.
 Autonomous maintenance is the first pillar of Total Productive Maintenance
(TPM). It is a way to provide your operators with the tools, including
digital, always-updated work procedures, they need to perform maintenance
tasks on their own equipment – emphasizing proactive and preventative
maintenance. By giving machine operators the means to carry out part of the
maintenance themselves, it leads to increased efficiency and productivity.
AUTONOMOUS MAINTAINANCE EXAMPLES.
PILLAR #2. PLANNED MAINTAINANCE.
 THIS PILLAR AIMS TO ACHIEVE ZERO BREAKDOWNS.
 PLANNED MAINTENANCE IS THE SCHEDULING OF MAINTENANCE
ACTIVITIES BASED ON OBSERVED BEHAVIOUR OF MACHINES SUCH AS
FAILURE RATES AND BREAKDOWNS.
 BY SCHEDULING THESE ACTIVITIES AROUND SUCH METRICS, THE
CYCLE OF BREAKDOWNS AND FAILURE IS BROKEN THUS CONTRIBUTING
TO A LONGER SERVICE LIFE OF MACHINES.
PLANNED MAINTAINANCE.
PILLAR #3. QUALITY INTEGRATION.
 THE QUALITY ASPECT OF MAINTENANCE IS VERY IMPORTANT BECAUSE IT HELPS
IN PREVENTING DEFECTS FROM MOVING DOWN THE VALUE CHAIN WHICH ONLY
LEADS TO A LOT OF REWORK.
 THE QUALITY MAINTENANCE PILLAR OF TPM ALSO INGRAINS IN THE
WORKFORCE THE HABIT OF FINDING THE ROOT CAUSE OF PROBLEMS INSTEAD
OF RUSHING TO SOLUTIONS THAT ARE NOT PERMANENT.
QUALITY MAINTENANCE OFFERS A NUMBER OF ADVANTAGES INCLUDING:
 TARGETED IMPROVEMENT ACTIVITIES ADDRESS QUALITY ISSUES THAT ARISE
FROM TIME TO TIME IN THE WORKPLACE BY COMING UP WITH PERMANENT
COUNTERMEASURES
 DEFECTS ARE MINIMIZED OR COMPLETELY ELIMINATED
 COST OF POOR QUALITY IS REDUCED BY GETTING QUALITY RIGHT THE FIRST
TIME. THIS HAPPENS BECAUSE ERRORS ARE CAUGHT BEFORE THEY MOVE
DOWN THE VALUE STREAM WHICH REDUCES THE AMOUNT OF REWORK THAT
HAS TO BE DONE TO CORRECT THEM
QUALITY INTEGRATION GRAPH.
PILLAR #4: FOCUSED IMPROVEMENT (KOBETSU KAIZEN)
 IN THIS PILLAR, CROSS-FUNCTIONAL TEAMS ARE ASSEMBLED WITH THE

MAIN WORKING ON PROBLEMATIC EQUIPMENT AND COMING UP WITH
IMPROVEMENT SUGGESTIONS.
 THE USE OF CROSS-FUNCTIONAL TEAMS IS IMPORTANT SO AS TO HAVE A
LARGE AND VARIED NUMBER OF EMPLOYEES INVOLVED SO AS TO BRING
IN DIFFERENT EXPERIENCE AS WELL AS VIEWPOINTS TO THE TABLE.
 THESE TEAMS ARE BETTER PLACED TO COME UP WITH SOLUTIONS TO THE
ISSUES THAT ARISE CONCERNING CRUCIAL MACHINES.
 THE TEAMS WORK TOGETHER TO MAKE SURE THAT ANY SOUTIONS THAT THEY
COME UP WITH ARE IMPLEMENTED AND ANY FOLLOW-UPS ARE COMPLETED
WITHIN THE AGREED TIMELINES.
 IT IS THEREFORE ADVANTAGEOUS AS QUICK GAINS ARE MADE.
PILLAR #5. EARLY EQUIPMENT MAINTAINENCE.
 The fifth TPM pillar of Early Management uses the experience gathered
from previous maintenance improvement activities to ensure that new
machinery reaches its optimal performance much early than usual.
 Such an approach has a positive impact on profitability of the company as
maintenance costs are dramatically reduced.
 The productivity as well as output quality of the machines is also
guaranteed from the very first day when the equipment is commissioned.
PILLAR #6. TRAINING AND EDUCATION.
 LACK OF KNOWLEDGE IN THE TOOLS CAN STAND IN THE WAY OF PROPER
IMPLEMENTATION LEADING TO MEDIOCRE RESULTS AT BEST AND FAILURE
AT WORST.
 WITHOUT PROPER TRAINING, TOOLS SUCH AS TPM CAN BE
MISUNDERSTOOD BY THE STAFF WHICH CAN RESULT IN DISASTROUS
RESULTS FOR THE COMPANY.
 THROUGH TRAINING, OPERATORS’ SKILLS LEVELS ARE RAISED TO THE
POINT WHERE THEY ARE ABLE TO CARRY-OUT BASIC MAINTENANCE
ACTIVITIES THAT WERE PREVIOUSLY THE PRESERVE OF MAINTENANCE
STAFF.
TRAINING AND EDUCATION STEPS.
PILLAR #7. SAFETY, HEALTH & ENVIRONMENT.
 WORKERS MUST BE ABLE TO PERFORM THEIR FUNCTIONS IN A SAFE

ENVIRONMENT DEVOID OF HEALTH RISKS CANNOT BE GAINSAID.
 THE HEALTH, SAFETY AND ENVIRONMENT PILLAR OF TOTAL PRODUCTIVE
MAINTENANCE ENSURES THAT ALL WORKERS ARE PROVIDED WITH AN
ENVIRONMENT THAT IS SAFE AND THAT ALL CONDITIONS THAT ARE HARMFUL
TO THEIR WELL-BEING ARE ELIMINATED.
 WHILE THE GOAL OF ANY ORGANIZATION IS TO PRODUCE VALUE FOR THE
CUSTOMER IN AN EFFICIENT AND PRODUCTIVE MANNER, THIS SHOULD BE DONE
IN A WAY THAT IS DOES NOT PUT TO RISK THE SAFETY OF WORKERS. IT IS
THEREFORE IMPORTANT THAT ANY SOLUTIONS WHICH ARE PUT IN PLACE
SHOULD CONSIDER THE WELL-BEING OF THE WORKER ABOVE ALL ELSE.
 WHEN WORKERS ARE IN A SAFE ENVIRONMENT, THEIR ATTITUDE TOWARDS
WORK CHANGES DRAMATICALLY WITH A RESULTANT INCREASE IN IMPORTANT
METRICS SUCH AS PRODUCTIVITY. THIS IS BECAUSE INJURIES OR FATALITIES
REDUCE WHEN THERE IS A CONCERTED EFFORT TO MAKE THE WORKPLACE AN
ACCIDENT-FREE ENVIRONMENT.
PILLAR #8. TPM IN ADMINISTRATION.
 Taking TPM to the administrative functions is the next logical step in the
total productive maintenance program so as to have the whole
organization speaking from the same page.
 The TPM principles can also be applied as stand-alone techniques to
improve the efficiency of these supportive functions. For example, if the
administrative functions are able to improve their order processing
procedures, then material will get to the shop-floor in a flawless manner
which will have a positive effect on the workflow.
REFRENCES:
 https://leanfactories.com/tpm-pillars-eight-pillars-of-total-productive-maintenan
ce/
 https://parsable.com/blog/manufacturing/what-is-autonomous-maintenance-7-
steps-to-successfully-implement/#:~:text=Autonomous%20maintenance%20is
%20the%20first,emphasizing%20proactive%20and%20preventative%20mainten
ance
 https://www.graphicproducts.com/infographics/pillars-of-tpm/
 https://www.sketchbubble.com/en/powerpoint-total-product-maintenance.html
 https://www.clarityvisualmanagement.com/technique/tpm-total-preventative-m
aintenance/
THANK YOU!

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TITLE: TPM AND IT’S 8 PILLARS.

THE MAJOR OBJECTIVES OF TPM ARE LISTED BELOW:

What Is Autonomous Maintenance?

 IN THIS PILLAR, CROSS-FUNCTIONAL TEAMS ARE ASSEMBLED WITH THE

 WORKERS MUST BE ABLE TO PERFORM THEIR FUNCTIONS IN A SAFE

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