The father of tpm was seiichi nakajima, who pioneered the approach in japan and exerted a major influence over the economic progress made by japanese manufacturers from the late 1970s. Total productive maintenance tpm is a maintenance program, which involves a newly defined concept for maintaining plants and equipment. The number, frequency, and severity of equipment breakdowns can be decreased with proper. This is a complex flowchart that tracks from fault or ftag to pm map or malfunction map. Dec 16, 2017 the stoppage time is the total time from the equipment stopping, until it starts again. Quality and maintenance of manufacturing systems are closely related functions of any organization. Maintenance and reliability workers are always striving for perfect. That foundation is achieved by employing 5s methodology. The early detection of developing problems is fundamental to preventive maintenance.
The goal of the tpm program is to markedly increase production while, at the same time, increasing employee morale and job satisfaction. It blurs the distinction between the roles of production and. Total productive maintenance tpm is one of the world class manufacturing tools that seeks to manage assets by involving everyone in the manufacturing organization. This waste is due to operators, maintenance personal, process, tooling problems and nonavailability of components in time etc. Total productive maintenance tpm implementation guide fiix. What is tpm total productive maintenance productivity. Total productive maintenance training tpm training online. Total productive maintenance powerpoint template sketchbubble. Implementing successful total productive maintenance tpm in. It is the bare minimum responsibilities of any operators and maintenance crew to conduct cleaning, inspecting, and repairing the area and equipment. Total productive maintenance and the basic pillars of tpm. Total productive maintenance tpm is a system designed to stabilize equipment performance and reliability. Produces and sells various tools for promoting tpm.
Performing manual oee calculations helps reinforce the underlying concepts and. Autonomous maintenance step 0 total productive maintenance. We expect our machines to work without failures, produce high quality output, at the same time consume very less manpower, raw materials, electrical energy, tools consumables etc, but this is highly difficult to realize in practice unless they approach is. Action plans for implementation of total productive maintenance shamsuddin ahmed and masjuki hj hassan faculty of engineering, university of malaya, malaysia abstract maintenance is an inevitable function in manufacturing plants. Tpm seminar will be held 19th march 2020, kyoto japan 20200128 news. Often referred to as total production maintenance or total productivity maintenance, the formal name for the tmp toyota introduced is total productive maintenance. The goal of the tpm program is to markedly increase production while, at the same time, increasing employee. To do that, small multidisciplinary teams improve stepbystep the overall equipment effectiveness of their production lines. Total productive maintenance training and programs have been proven to help workers from plantfloor employees to senior executives incorporate maintenance into the everyday performance of the facility, detect developing problems earlier, mistakeproof equipment and reduce breakdowns. Tpm leads to reduced downtime, fewer stops and breakdowns, and a smaller likelihood that products will suffer quality defects during the manufacturing process. Total productive maintenance is an innovative approach to maintenance that optimizes equipment effectiveness, eliminates. It is the principal responsibility of planned maintenance to eliminate equipment failures. Tpm100 intro to tpm study guide introduction to total productive maintenance april 2006 tpm100sg00100. By then nippon denso had made quality circles, involving the employees participation.
Action plans in implementation of total productive maintenance. Implementing successful total productive maintenance tpm in a manufacturing plant ignatio madanhire, and charles mbohwa abstract this study examines the impact of total productive maintenance tpm implementation on an organization. Cudney and others published total productive maintenance. Jan 01, 2014 as total productive maintenance becomes more widespread auditors needs to understand its role in the audit process. Manufacturing plants are exposed to newer and rapidly changing paradigms. This oee highlights the actual hidden capacity in a organization. Total productive manufacturing tpm overall equipment effectiveness oee model. Total productive maintenance tpm is a strategy that operates according to the idea that everyone in a facility should participate in maintenance, rather than just the maintenance team. Total productive maintenance tpm concentrates on productivity improvement, primarily by way of maximizing the availability of equipment. To keep value flowing, and maximize your sales and margin contribution, you must engage everyone in establishing and maintaining equipment and process reliability. Using techniques and tools such as cmms and total productive maintenance, his focus is on helping clients develop world class maintenance policies and practices.
The design and installation of equipment as well as how it is operated and maintained affect the oee. Performance speed loss ideal cycle time operating time total pieces quality quality loss good pieces total pieces oee availability x performance x quality. This powerpoint will help you to investigate if the introduction of tpm will help you reduce lost time on operating equipment to a tune of 30% or better. Total productive maintenance tpm is the process of using machines, equipment, employees and supporting processes to maintain and improve the integrity of production and the quality of systems. Over a period of time two concepts have emerged which are total productive maintenance tpm and total quality management tqm along with other concepts to achieve world class manufacturing system. The japan institute of plant maintenance jipm tpm excellence awards are the global benchmark for businesses achieving this level of sustained success. An introduction to total productive maintenance tpm. Aug 16, 2019 tpm total productive maintenance applies a series of techniques that ensure equipment is always available to turn out products of the desired quality at their maximum capacity or, in other words, to maximize the oee overall equipment effectiveness. Total productive maintenance tpm how to implement in a. Scheduled maintenance or scheduled restoration 223 scheduled replacement or scheduled discard 226 the rcm pm analysis 227 the rcm decision diagram 228 failure is unacceptable. Oee is a metric to evaluate the effectiveness of your tpm improvements.
Tpm total productive maintenance engages operators to improve. The concept of total productive maintenance tpm has been introduced and developed by japanese in 1971. Total productive maintenance workshop s a partners. That is the method of training operators to get involved in maintenance task too. A guide to total productive maintenance greycampus.
The goal of the tpm program is to markedly increase production while, at the same. The approach includes a number of methodologies still widely used today such as the six big losses, and is well suited to the smart factory and its iot use cases. Total productive maintenance tpm is a maintenance program which involves a newly defined concept for maintaining plants and equipment. An introduction to total productive maintenance tpm plant.
Certainly, it is not a quick fix and depending on the size and complexity of the companys operations, it may take years to fully implement. Total productive maintenance is a system that will transform the way an organization operates. This is done to add value to the business organization. Jul 04, 2018 the implementation of total productive maintenance starts with creating a strong base read work environment you can build upon. Evolved in japan since 70s from toyota for companies who desperately want to win in todays competition. By giving ownership and responsibility of equipment and processes to the right employees, equipment breakdowns are reduced. Without effective leadership that links tpm efforts to the business and holds people accountable for performing highly specified work, equipment performance and reliability will continue to decline and tpm initiatives. Total productive maintenance tpm is a series of methods that ensures every piece of equipment in a production process is always able to perform its required tasks so that production is never interrupted. Total productive maintenance or total productive manufacturing is a continuous improvement strategy that embraces all aspects of an organisation. How to calculate overall equipment effectiveness oee. Total productive maintenance is an innovative approach to maintenance that optimizes equipment effectiveness, eliminates breakdowns and promotes autonomous maintenance by operators through daytoday activities involving total workforce bhadury, 2000.
Download the guide to total productive maintenance ebook. This concept was first introduced by ms nippon denso co. The basic measure associated with total productive maintenance tpm is the oee. Everybody should follow the work instructions strictly. The three goals of tpm are zero unplanned failures, zero product defects, and zero accidents. Tpm total productive maintenance is a holistic approach to equipment maintenance that strives to achieve perfect production. The aim of productive maintenance was to maximize plant and equipment effectiveness to achieve optimum life cycle cost of production equipment. Maintenance prevention and maintainability improvement gave birth to productive maintenance.
Tpm emphasizes proactive and preventative maintenance to maximize the operational efficiency of equipment. The successful and sustainable implementation of total productive maintenance also known as tpm should be a key concern for any conscientious plant manager or production leader. Implementing total productive maintenance with the help of a cmms. This came in response to the maintenance and support problems in commercial factory. Total productive maintenance tpm is a system of maintaining and improving the integrity of production, safety and quality systems through the machines, equipment, processes, and employees that add business value to an organization. Total productive maintenance tpm summary of tpm tpm was developed in the 1970s as a method of involving machine operators in the preventive maintenance of their machines a reaction to increasing specialization and centralization of the maintenance function that had created divisionoflabor barriers between operators and the maintenance of.
Implementing successful total productive maintenance tpm in a manufacturing plant ignatio madanhire, and charles mbohwa abstract this study examines the impact of total productive maintenance tpm implementation on an organization in terms of productivity and quality levels. It is a comprehensive, teambased, continuous activity that enhances normal equipmentmaintenance activities and involves every worker. These losses were captured in the overall equipment effectiveness oee. The tpm program closely resembles the popular total quality management. It can be considered as the medical science of machines. Total productive maintenance, goal, main aspects, preventive corrective inbuilt maintenance. The benefits of tpm and how to start putting your tpm program into action one step at a time.
The tpm element most emphasized on in malaysian electrical and electronic. Total productivity maintenance project freebooksummary. As an integral approach to business solutions tpm total productive maintenance is a core support programme affiliated with the japanese institute of plan maintenance jipm, considered to be the global leading body, tpm is not just a professional maintenance approach but also a cultural transformation programme. Tpm focuses on keeping all equipment in top working condition to avoid breakdowns and delays in manufacturing processes. Oee is not an exclusive measure of how well the maintenance department works. Introduction to total productive maintenance study guide tpm100sg00100. Total productive maintenance tpm is a lean manufacturing approach developed in japan in 1971. Tpm can be of great value and its target is to improve core business processes. An introduction to total productive maintenance faculty. Like other manufacturing tools, it is implemented in systematic phases. Tpm or we will say total productive maintenance, philosophy is mostly oriented from manufacturing industry and this page will explain aspect of tpm according to that. Terry wireman is a widely known and respected consultative educator, specializing in the improvement of maintenance and asset management for clients.
How to implement a total productive maintenance plan tpm. This approach uses the skills of all employees and seeks to incorporate maintenance into the everyday performance of a facility. Total productive maintenance is a system of maintaining and improving the integrity of production, safety and quality systems through the machines, equipment, processes, and employees that add business value to an organization. These stoppages should be grouped into equipment and other failures. An introduction to total productive maintenance tpm j. Japan institute of plant maintenance just another wordpress. To implement total productive maintenance tpm it is necessary to assess the magnitude of different types of production losses, in order to direct activities and allocate resources in an optimal way. To enable total productive maintenance, use a cmms solution. Tpm focuses on keeping all equipment in top working condition to avoid breakdowns and delays in manufacturing.
Total productive maintenance tpm focuses on getting managers, maintenance personnel and equipment users all working together to prevent equipment problems and reduce expenditures. Total productive maintenance tpm is a method of maintaining and improving the integrity of production and quality systems through the machines, equipment, employees and the supporting processes. Equipment failures are stoppages resulting from equipment deterioration. Case1 karakuri kaizen exhibition in thailand case2 tpm seminar in india. Tpm total preventative maintenance 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 aims to reduce six significant losses in the maintenance process. The role of administrative and support departments. Total productive maintenance tpm is the process of maximizing equipment effectiveness through the active involvement of all supporting departments. The primary goals of tpm are to eliminate waste caused by accidents, emergency and unscheduled downtime, defects and speed losses. Total productive maintenance workshop, key outputs. It implies improving production and quality systems through the machines, equipment, processes, and. Total productive maintenance tpm is an approach to equipment maintenance that aims to achieve a perfect production process by increasing productivity, efficiency, and safety. It is teambased preventive and productive maintenance and involves every level, from top executive to the floor operator. Our curriculum covers a full range of industrial, facility, and building maintenance topics.
The goal of total productive maintenance tpm is to improve overall productivity by optimizing equipment availability. This course is designed to demonstrate the goals, methods and practical benefits of total productive maintenance tpm with a focus on predictive maintenance. Total productive maintenance in supply chain management. What total productive maintenance is and how it works. Total productive maintenance is a methodology used to improve the quality and the integrity of production by enhancing the various components of a company including the employees, processes and equipment. Total productive manufacturing tpm overall equipment.
Tpm improves equipment effectiveness lean production. Total productive maintenance tpm and its subset of autonomous maintenance are described as allencompassing, companywide, teambased practices for decreasing equipmentrelated waste and losses linked to downtime, speed degradation, fixturewear, and. Our instructors are seasoned industry experts and fieldexperienced educators. Total productive maintenance tpm implementation in a. Implementing successful total productive maintenance. Tpm total productive maintenance applies a series of techniques that ensure equipment is always available to turn out products of the desired quality at their maximum capacity or, in other words, to maximize the oee overall equipment effectiveness. That is part of the meaning of total in total productive maintenance. Implementing total productive maintenance with the help of.