Monday 10 December 2018

What is TPM?

A 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. TPM can be of great value and its target is to improve core business processes.


History of TPM

TPM is an innovative Japanese concept. The origin of TPM can be trace back to 1951 when preventive maintenance was introduce in Japan. However, the concept of preventive maintenance was taken from USA. was the first company to introduce plant wide preventive maintenance in 1960. Preventive maintenance is the concept wherein, operators produce goods using machines and the maintenance group was dedicate with work of maintaining those machines, however with the automation of, maintenance became a problem as more maintenance personnel were require. So the management decide that the routine maintenance of equipment would be carry out by the operators. (This is Autonomous maintenance, one of the features of TPM). Maintenance group took up only essential maintenance works.


Thus which already follow preventive maintenance also add Autonomous maintenance done by production operators। The maintenance crew went in the equipment modification for improving reliability. The modifications were made or incorporate in new equipment. This lead to maintenance prevention. Thus preventive maintenance along with Maintenance prevention and Maintainability Improvement gave birth to Productive maintenance. The aim of productive maintenance was to maximize plant and equipment effectiveness to achieve optimum life cycle cost of production equipment.

By then Nippon Denso had made quality circles, involving the employee’s participation. Thus all employees took part in implementing Productive maintenance. Base on these developments was award the distinguish plant prize for developing and implementing TPM, by the Japanese Institute of Plant Engineers ( JIPE ). Thus of the Toyota group became the first company to obtain the TPM certification.

How Does TPM Work?

  • Complete company involvement- Executive Management to Associates

  • Clear Understanding– Training

  • Goals and Objectives – Keep the end in mind

  • Focus Natural Work Groups – Empowerment

  • Focus Improvements – Customer Concerns, Downtime, Internal Auditing

TPM Basic Concepts and Structures

As note earlier in the is paper, the working definition for TPM is; Total Productive Manufacturing is a structure equipment-centric continuous improvement process that strives to optimize production effectiveness by identifying and eliminating equipment and production efficiency losses throughout the production system life cycle through active team-based participation of employees across all levels of the operational hierarchy. The key elements of this definition will be investigate further.

  • Structure Continuous Improvement Process.

  • Optimize Equipment (Production) Effectiveness.

  • Team-base Improvement Activity.

  • Participation of employees across all levels of the operational hierarchy.

Total Productive management?

TPM (Total Productive Management) is the activities design to restore equipment to optimal conditions which is base on Total Participation, everybody involve, from Top management into First Line Operators in all department.

  1. Focuse Improvement

  2. Autonomous Maintenance

  3. Plan Maintenance

  4. Quality Maintenance

  5. Initial phase Control

  6. Safety Environment

  7. Training Education

  8. Office TPM

TPM Tools

The TPM as a tool to achieve:

  1. Total Customer satisfaction and highest quality at globally level & competitive prices.

  2. World class manufacturing by multi skill development of employees.

  3. Zero breakdown by reducing losses, improving design.

  4. Customer satisfaction by reducing Customer complaints to zero PPM.

  5. Create a safe & pleasant working environment.

  6. To improve the methodology of the machining and to ensure single piece flow.

Basic Idea of TPM

  1. Making profitable company Constitution: -Pursuit of Economic Efficiency, Zero- Defects, Zero- Failures.

  2. Philosophy of prevention (Prevent Accidents from happening) -MP –PM-CM.

  3. Participation by All -Overlapping Small Group Organization, Autonomous Maintenance by Operators.

  4. At Plant, In Process -Keep the equipment in optimal condition, Visual Controls, making a clean workplace.

  5. Automation, Unmanned Operation. -Making a workshop that requires no manpower.

Intangible benefits of TPM

  • After introduction of Autonomous maintenance activity, operators take care of machines by themselves without being order to.

  • With achievement of zero breakdowns and zero defects, operators get new confidence in their own abilities.

  • Workplaces that use to be cover with oils & chips are now so clean and pleasant as to almost unrecognizable.

  • Improve image of the company, leading to the possibility of increase orders.

TPM & Automation

Plants often evolve through new technologies addition of new equipment and revamping of old ones. It is important that new equipment and technologies fit in seamlessly into the previously install equipment and system. Increasing the level of automation reduces dependence on manual procedures and inadvertent mistakes.

Operational accuracy and repeatability are important to plants to be predictable and reliable. Increasing automation can substantially reduce maintenance costs and improve product quality. Human efforts thus save, can then be direct to generate innovative ideas for reducing cycle times and cutting down process loss at every steps.

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