Total Productive Maintenance

Importance of TPM which stands for Total Productive maintenancefor Liberalization of global economy has resulted tough competition in global market and for the sustainability in market for any product or service, the optimization of resources and costs in all sorts is required. The global competition is based on the innovation of advanced products, processes etc. and technology support is the essential requirement for any advancement in product or process where concept of Total productive maintenance has very much relevance today where it focus on improvement in equipment availability, performance and quality with assuring health and safety of employees and protection of environment.TPM provides a method for the achievement of world class levels of overall equipment effectiveness through people and not through technology or systems alone. It includes the organizational structures, human interactions, analytical tools and success criteria associated with the implementation of Total Productive Manufacturing programs.

Keywords: Availability, Efficiency, Performance, Preventive maintenance, Total productive maintenance. I. INTRODUCTION TPM adapted from TQM, which evolved as a result of Dr. W. Edwards Deming’s influence on Japanese industry. When the problems of plant maintenance were examined as a part of the TQM program, Preventive Maintenance was introduced in Japan in the late 1950s. M/s Nippon Denso Co. Ltd. of Japan, a supplier of M/s Toyota Motor Company, Japan became the first company to obtain the TPM certification. Objectives of TPM is zero breakdown, zero losses, zero defect and zero health hazard and hence increase quality and productivity in manufacturing industries. Reference [1] a major benefactor of TPM, has defined TPM as a new approach to maintenance that optimizes equipment effectiveness, promotes autonomous maintenance and eliminates breakdowns by operators through day-to-day activities.

An Introduction to Total Productive Maintenance (TPM) - J. Venkatesh ( ven_hal@yahoo.com ) In today’s industrial scenario huge losses/wastage occur in the manufacturing shop floor. This waste is due to operators, maintenance personal, process, tooling problems and non-availability of components in time etc. Other forms of waste includes idle machines, idle manpower, break down machine, rejected parts etc are all examples of waste. The quality related waste are of significant importance as they matter the company in terms of time, material and the hard earned reputation of the company. There are also other invisible wastes like operating the machines below the rated speed, start up loss, break down of the machines and bottle necks in process. Zero oriented concepts such as zero tolerance for waste, defects, break down and zero accidents are becoming a pre-requisite in the manufacturing and assembly industry. In this situation, a revolutionary concept of TPM has been adopted in many industries across the world to address the above said problems. This chapter deals in length about this TPM.

Keywords-- Five S, Visual management, TQM, TPM I. I NTRODUCTION HE worldwide industrial focus is over improvements in their technology as well as systems of working towards achieving competitive price for their products and earning customer confidence. Nowadays, Total Quality Management, Total Productive Maintenance, Toyota Production System, Just in Time, Six Sigma etc., have become global words which are known for their significant effects over manufacturing effectiveness and this too is proved by renowned companies.

The manufacturing industries have gone through significant change in the last two-three decades and the competition has increased very rapidly. The main focus of the customers is on product quality, product delivery time and the cost of product. The cost of operation and maintenance should be economical. The cost of operation and maintenance can make or break a business, especially with today’s increasing demand on productivity, availability, quality, safety and environment Total productive maintenance (TPM) is a maintenance program which involves a newly defined concept of maintaining plants and equipments. TPM is a methodology that aims to increase the availability of existing equipment hence reducing the need for further capital investment. .It sets out to achieve these goals by analysis of previous historical records of product defects, equipment failure and accidents. A detailed case study on the journey of TPM in an auto- sector industry namely Sona Koyo Steering Systems Limited, Gurgaon is done. Normally the TPM implementation is a three to four years process and in Sona Koyo Steering, Gurgaon it implemented in 2000. Sona Koyo Steering, Gurgaon initiated TPM implementation through a consultant with an aim to implement all the eight pillars of TPM in a phased manner. The objective of this thesis is to study the implementation plan followed by Sona Koyo Steering, Gurgaon and find out the tangible as well as intangible benefits derived at different stages. The objectives, targets and implementation method of all the eight pillars are studied and enumerated. The case study can give insight and help the other industries in implementing TPM successfully in an efficient manner.

ABSTRACT: Literature on maintenance management practices evolution from total productive maintenance to world class maintenance has so far been very limited. This paper reviews a large number of papers in this field and suggests the retrospective growth in this field. Subsequently, the need of maintenance, TPM attributes with it’s different pillars, shortcoming of TPM are discussed in details then the world class maintenance system with its components, modules, factors for success and how to implement the world class maintenance system in any industry are discussed. A survey of CMMS Implementation is discussed by considering factors affecting implementation success, important aspect of CMMS implementation and benefits obtained from CMMS implementation. The paper provides many references and case studies on maintenance management. It gives useful references for maintenance management professionals and researchers working on maintenance management.

ABSTRACT: Literature on maintenance management practices evolution from total productive maintenance to world class maintenance has so far been very limited. This paper reviews a large number of papers in this field and suggests the retrospective growth in this field. Subsequently, the need of maintenance, TPM attributes with it’s different pillars, shortcoming of TPM are discussed in details then the world class maintenance system with its components, modules, factors for success and how to implement the world class maintenance system in any industry are discussed. A survey of CMMS Implementation is discussed by considering factors affecting implementation success, important aspect of CMMS implementation and benefits obtained from CMMS implementation. The paper provides many references and case studies on maintenance management. It gives useful references for maintenance management professionals and researchers working on maintenance management.

effectiveness (OEE) in boiler plant. Results of investigation demonstrated the significant 5% improvement in OEE. Amin et al. (2013) developed the technology by incorporating concepts of lean manufacturing, total productive maintenance (TPM) and low cost automation techniques to increase their competitiveness. Proper understanding of process requirements and tool designing in accordance with process requirement are the two major factors which help to down size the machine and to identify unnecessary parts. By applying these techniques on BC-21 machine, Munjal Showa is able to reduce the space used by 68 percent, break downs by 93 percent, cycle time by 48 percent and an increase in productivity by 52 percent.

The main aims of study of this paper understand TPM methodology and tools of TPM.Implementation of TPM is not overnight. It is day-to-day activity with involvement of all employees. It needs top management commitment. The performance measurement for production process is very important for sustaining firms. Managers make decisions from this correct evolution. Therefore, appropriate measurement is necessary. The accuracy of global performance evolution is essential to improve and succeed in business goal. One of the important and widely used metrics of performance in manufacturing is OEE especially for firms applying TPM [3].Total productive maintenance is one of the best tools for making our industries competitive and effective in the field of maintenance .TPM may be the only thing that stands between success and total failure for some companies [11].

ABSTRACT Maintenance is an inevitable function in manufacturing plants. Manufacturing plants are exposed to newer and rapidly changing paradigms. Today, a productive maintenance strategy and programs have utmost importance in order to discover the useable but hidden resources in an organization. A well-conceived action plan is a pre-requisite to unearth those potential treasures. This paper presents a brief action plan for implementation of total productive maintenance (TPM). From an empirical study, conducted by these authors, it is revealed that demanding quality in maintenance practices is still a far cry. Lack of understanding of the method and implementation guidelines appear to be the major factors responsible for this state. Therefore, it is strongly felt that TPM deserves more attention both in practices and research.

1,2,3,4 Bhilai Institute of Technology, Durg Abstract— Maintenance costs can account for 15 to 40 % of total manufacturing costs. These costs can be minimized by the proper maintenance management. Quality and Maintenance of manufacturing systems are closely related functions of any organization. Today’s competitive environment requires much more effective equipment management. Total productive maintenance (TPM) and Total Quality Management (TQM) are the new approaches along with other concepts to achieve World Class Manufacturing system. The goal of the any TPM program is to improve productivity and quality along with increased employee morale and job satisfaction. In this paper experience of implementing Total Productive Maintenance is shared and investigated for an industry’s particular part known as Bright Bar shop. Overall Equipment Effectiveness is used as the measure of success of TPM implementation. The various losses linked with the overall equipment effectiveness are determined. The TPM pillars are implemented in order to eliminate losses and to improve productivity. The study found that focused TPM implementation over a sensible time period can advantageously contribute towards understanding of significant manufacturing performance improvements.

Bennett and Lee [3] proposed the objective of total productive maintenance to maximize plant and equipment effectiveness, and to create a sense of ownership for operators and promote continuous improvement through small group activities involving production engineering and maintenance personnel. This paper described and analysed a case study of TPM implementation at a newspaper printing house in Singapore. However, rather than adopting more conventional implementation methods such as employing consultants or through project using external training, a unique approach was adopted based on action research using a spiral of cycles of planning, acting observing, and reflecting. Finally, the paper identified the characteristics associated with the action research method when was used to implement TPM and discusse the applicability of the approach in related industries and processes [3].

VII. P ROBLEM S TATEMENT To improve the operational status of a company, there are required strategies that aim to eliminate waste, ensure quality and reduce costs. The approach to Total Productive Maintenance (TPM) leads to the development of methods and management tools that promote organizational change, especially at human resources level. TPM philosophy supports a culture in which the operator develops a sense of belonging towards the equipment that he handles, getting to know them better, ensures a climate of continuing efforts towards the targets of belonging, developing skills and competencies, to continually stimulate the operators action improvement (Willmott, 1994). Development of one of TPM pillars, autonomous maintenance, is at the root of these changes. In this case, through the sense of belonging, it is promoted the interest of operators for their work and performance, providing organizational advantages at all levels. Ahmedand Siong (2007) report that TPM implementation not only improves availability and confidence in the equipment, but also provides progress and increasing in production, in product quality development and develops a team spirit culture, while it also increases work capacity among individuals. In addition to the operational performance improvement of the factory floor, there is an expansion at employees‘ attitudes levels.

izaidin@utem.edu.my ABSTRACT Total Productive Maintenance or TPM is an advanced manufacturing technique that focuses on maximizing the Overall Equipment Effectiveness or OEE of any asset or capital equipment utilized in the production of goods and services. While the basic components of TPM have been existence for decades, few companies are able to assemble the components into an overall strategy. Many companies will partially implement some of the components but never realize the full benefits that can be achieved through TPM. In addition, staffs at production area need to make sure that they manage to strike the demand on time. Since the production area conquered by the machine, there will be risk that the machine not work properly, damaged and corrupted. That’s the reason why TPM has been design to assist the manufacturing in production area to increase the performance of the equipments. This case study, we do in order to find out about the difference of the result that affects OEE before and after the TPM being implemented in manufacturing industries. Improvement will be made after the abnormal elements have been detected, so that it can be directly corrected. Analyzing and identify the elements will give impact on the OEE result. The approach methods in this study is experimental study through instruments used to collect data are observation and calculation. To calculate the OEE, Microsoft Excel is commonly be used. Hence, TPM is a tool in helping firm to achieve an optimal manufacturing process. By being able to achieve this level of maintenance, an organization will be able to make such a competitive advantages brought by TPM philosophy, thus producing such high quality of manufacturing product that manage to satisfy customers and subsequently generating greater profits.

Parit Raja, Johor, Malaysia Abstract— Nowadays, consumers expect manufacturers to provide excellent quality, reliable delivery and competitive pricing. This demands that the manufacturer’s machines and processes are highly reliable. In order to possess highly reliable machines to make sure smooth manufacturing process, many organizations have implemented Total Productive Maintenance (TPM) as the enabling tool to maximize the effectiveness of equipment. Overall Equipment Effectiveness (OEE) is used as a measure when evaluating the result of TPM. This paper has found out the difference between before and after the TPM implementation to OEE result. Comparison between before and after the implementation of TPM was carried out to see the difference that TPM can bring to an organization. Elements that constitute the OEE equation have been analyzed and indentified which one that affected OEE result. After identifying, improvement has been made on that element so that OEE result would be improved ultimately. Microsoft Excel was used to analyze data obtained and calculate OEE. Hence, TPM is a useful tool in helping firm to achieve optimal manufacturing process.

The resultant de-motivation in the operator workforce has been suggested to be responsible for the observed poor house- keeping, high defect rate, associated frequent breakdowns and unplanned work stoppages in the case study plant. To address these challenges, a human resources based maintenance approach is required to provide employees with confidence which in turn will be imparted towards overall equipment/machine efficiency and profitability as put across in the Total Productive Maintenance (TPM) philosophy [11].

Total Productive maintenance has been found to be an effective method of continually improving OEE in manufacturing plants (Patel & Thakkar, 2014). It is primarily developed from the preventive maintenance concept meant for plant maintenance management (Singh, Shah, Gohil, & Shah, 2013). The implementation of TPM programs acts to eradicate certain losses on the production line which in-turn enhances the factors that affect OEE thereby positively impacting OEE at the same time (Patel & Thakkar, 2014). Appropriate TPM incorporation in manufacturing organisations has been directly linked to significant decline in equipment breakdowns and quality related product rejects (Patel & Thakkar, 2014). Theory extends to state that through the involvement of machine operators in the establishment and execution of preventive plant maintenance systems for production equipment, employee morale is raised and individuals take responsibility in taking preventive action against possible failures (Sahu, Meghraj, & Chandrakar, 2016).

CHAPTER 1 INTRODUCTION 1.1 Introduction Globalization and economic turbulence have increased pressure on manufacturing firms to perform in cost efficient ways that are able to satisfy the ever changing need of their customers. Costs of production are often linked to maintenance related activities (maintenance labor and maintenance costs) and cost incurred due to the production losses (Blanchard, 1997). Bamber et al. (1997) reported that effective maintenance strategy significantly adds value to the production activities and subsequent business. One of the well-known innovative maintenance programs adopted by manufacturers is the Total Productive Maintenance (TPM). It was proven as one of the innovative approach for maintenance since it help to optimizes equipment effectiveness, eliminates breakdown and promotes autonomous maintenance via day today activities involving the firm’s total workforce. Since it was introduced a few decades ago, it has attracted many companies in multi- industries to implement it.

In modern manufacturing industries role of maintenance are becoming significant that companies want the maintenance to be a business element that generates profits. It is common that, maintenance cost is bigger part of any operational budget while 30 percent of total manpower of a manufacturing will belong to maintenance and operation department (Jain et al., 2015). Total Productive Maintenance (TPM) is a manufacturing program that maximizes the effectiveness of machine over lifespan of the machine by involvement of overall workforce. By improving employees’ skills and enhancing technology of equipment TPM will improve the technological base of the company. Besides that, TPM also plays role in improving capability of the organization by enabling cross functional learning and improving individuals’ problem-solving skills (Ferrari et al., 2002).

Abstract -- Global performance evaluation is the most important in the field of continuous improving of the production process. Overall Equipment Effectiveness is one of the performance evaluation methods that are most common and popular in the production industries. This paper focuses on a study of total productive maintenance and evaluating overall equipment effectiveness. The calculation of the overall equipment effectiveness in S alt Company (Emisal) in Egypt is carried out.