Tutorial that explains the use of lean and total productive maintenance. The goal of total productive maintenance tpm is to improve overall productivity by optimizing equipment availability. Etman introduction to total productive maintenance tpm. It can be considered as the medical science of machines. Tpm seeks to maximize equipments effectiveness throughout the life time of that equipment. Wikipedia describes one of the main objectives of total productive maintenance is to increase the productivity of plant and equipment with a modest investment in maintenance. Total productive maintenance is keeping all the equipment in top condition to minimise the chance of delays, breakdown during the manufacturing process. Zero breakdown through total productive maintenance tpm. The goal of the tpm program is to remarkably increase production while, at the same time, increasing employee morale and job satisfaction. Total productive maintenance 1 total productive maintenance. An optimal maintenance policy strikes a balance between the costs of breakdown and preventive maintenance so that the total cost of maintenance is at a minimum.
Total productive maintenance tpm is an approach to equipment maintenance that aims to achieve a perfect production process by increasing productivity, efficiency, and safety. Tpm is used by various industries, but works especially well for manufacturersand it can deliver compelling results over time. Thus all employees took part in implementing productive maintenance. Achieve zero defects, zero breakdown and zero accidents in all functional areas of. Jan 07, 2020 total productive maintenance is a proactive approach that deals in the comprehensive management of processes, people, environment and systems. It is software oriented, employees participation and it is hardware oriented. An introduction to total productive maintenance tpm.
Total productive maintenance or tpm software, equipment. One of the most important measurements of total productive maintenance is overall equipment effectiveness oee, which measures availability, performance efficiency, and quality. Achieve zero defects, zero breakdowns and zero accidents with. Many executive jobs today require that their employees have at least a basic understanding of total productive maintenance. This approach uses the skills of all employees and seeks to incorporate maintenance into the everyday performance of a facility. Implementing total productive maintenance with the help of a. Tpm brings maintenance into focus as a vital part of business. Tpm pro is the amazing new webbased software for monitoring and controlling all your maintenance activities for your machines. Total productive maintenance tpm is a holistic approach to equipment maintenance. 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. Aug 16, 2018 total productive maintenance tpm for everts 20aug2018 1.
This is done to add value to the business organization. Total productive maintenance powerpoint template sketchbubble. Growth 500 top 20 best places to work b corp certified carbon zero certified. T r srinivas3, raghavendra m j4 1assistant professor, department of mechanical engineering, p. Get a personalized walk through of the fiix maintenance management platform. This video provides an introduction to total productive maintenance and the 8 pillars of tpm. But the total productive maintenance tpm approach is bringing manufacturers closer to making this a reality. Evertsthe balloon company no 23, jalan usaha 6, kaw. 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 maintenance definition, meaning, objectives. Tpm merupakan suatu sistem perawatan mesin yang melibatkan seluruh bagian dan anggota organisasi, termasuk operator produksi. In the organizations which have implemented the process of total productive maintenance, the entire team plays an essential role as the responsibilities are shared between operators and maintenance experts. Ppt total productive maintenance powerpoint presentation. The tpm program significantly increases labor and capital productivity while, at the same time, increases employee morale and job satisfaction.
Total productive maintenance and the basic pillars of tpm. Planned maintenance is performed by periodically evaluating the. Total productive maintenance tpm for everts 20aug2018. Total productive maintenance tpm is a maintenance program which involves a newly defined concept for maintaining plants and equipment. The objective of the total productive maintenance tpm is to enhance. Each of these pillars has a video dedicated to it and you. Total productive maintenance is a holistic approach to equipment maintenance to achieve the goal of zero defects, zero breakdowns, and zero accidents. Total productive maintenance tpm how to implement in a. The first step is to explain that a repair does not finish when they fix the machine, but it finishes when they take action to prevent the recurrence. To enable total productive maintenance, use a cmms solution. Total productive maintenance tpm linkedin slideshare. True while breakdowns occur randomly, their frequency is somewhat predictable through such tools as the product failure rate, mtbf, and the breakdown costs model. Total productive maintenance tpm tutorial moresteam. Total productive maintenance tpm is the process of maximizing equipment effectiveness through the active involvement of all supporting departments.
Total productive maintenance tpm is the idea that everyone in a facility. Tpm improves equipment effectiveness lean production. In this type of maintenance, no care is taken for the machine, until equipment fails. Sep 10, 2018 zero breakdown activities the biggest challenge during the tpm implementation is to change the tradesmen mind set from the reactive approach firemen to a proactive approach machine physician. Implementing total productive maintenance tpm with cmms. The goal of the tpm program is to markedly increase production while, at the same time, increasing employee. Jul 18, 2016 this video provides an introduction to total productive maintenance and the 8 pillars of tpm. Sasaran program training total productive maintenance.
College of engineering, mangaluru, karnataka state, india 574153. Total productive maintenance tpm is a maintenance program, which involves a newly defined concept for maintaining plants and equipment. Thus to say tpm succeeds not because of its engineering techniques but because of its reliance on training and team empowerment 9. It is a system of maintaining and improving the integrity of production and quality systems through machines, equipment, processes and employees to add business value to the organization. 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. Manufacturing plants are exposed to newer and rapidly changing paradigms. The goal of the tpm program is to markedly increase production while, at the same time, increasing employee morale and job satisfaction. Perindustrian, 75450, ayer keroh, melaka tel 0624800 tpm total productive maintenance presented by. The three goals of tpm are zero unplanned failures, zero product defects, and zero accidents. It consists of a series of elementary tasks data collections, visual inspections, cleaning, lubrication, retightening screws, for which no extensive training is necessary, but perhaps only a brief training.
Tpm also helps to improve your firsttime through, or ftt, quality levels. Total productive maintenance offers a system that focuses on deterioration prevention and maintenance reduction. By then nippondenso had made quality circles, involving the employees participation. Each of these pillars has a video dedicated to it and you can find these videos and many more on our. The biggest challenge during the tpm implementation is to change the tradesmen mind set from the reactive approach firemen to a proactive approach machine physician. Planned maintenance activities are essential to the prevention of equipment breakdown. It was developed to support tpm initiatives by accurately tracking progress towards achieving perfect production. Ive seen organizations with zero breakdowns or failures, and it took them seven to eight years. This type of maintenance is the based on tpm total productive maintenance. 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. The most popular method is total productive maintenance tpm.
Total productive maintenance tpm is a system of maintaining and improving the integrity of production and quality systems through the machines, equipment, processes, and employees that add business value to the organization. Total productive maintenance tpm is a unique approach to equipment maintenance. Tpm can be of great value and its target is to improve core business processes. Achieve zero defects, zero breakdown and zero accidents in all.
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. An implementation of real time total productive maintenance software. Factory managers want highperforming machines that never break down and switch easily from one product to another. Perfect production with zero breakdowns, zero defects and zero accidents may seem like a dream. Its something that is seemingly unreachable, but it is the ultimate goal of any organization that decides to implement total productive maintenance.
Effect of total productive maintenance tpm implementation. Jun 21, 20 as a companywide initiative, total productive maintenance tpm maximizes the effectiveness of equipment. The total productive maintenance certification was designed to teach someone with little to no knowledge of tpm the basic skills needed to function during a tpm process. Zero breakdown activities total productive maintenance. The tpm program closely resembles the popular total quality management. Implementing successful total productive maintenance tpm in. Tpm total productive maintenance the big idea getting operators involved in maintaining their own equipment, and emphasizing proactive and preventive maintenance will lay a foundation for improved production fewer breakdowns, stops, and defects. Jul 04, 2018 who wouldnt be proud of a maintenance team that experiences no accidents and has zero unexpected machine breakdowns. Sasaran penerapan tpm adalah tercapainya zero breakdown, zero defect, dan zero accident, dengan demikian memaksimalkan efektivitas penggunaan mesin. In todays industrial environment big losses happen in manufacturing sector.
Learn how fiix partners with you to evaluate, purchase, implement, and integrate cmms software. It supports a total productive maintenance tpm approach by providing proactive online information on maintenance related data on your machinery. One thing is for certain, implementing total productive maintenance is a big challenge, meet that challenge and deliver superior results. Maintenance downtime is included in manufacturing scheduling, and in many cases, becomes an integral part of the manufacturing process. Total productive maintenance is a maintenance philosophy, but there are tangible kpis that accompany it. This type of maintenance could be used when the equipment failure does not significantly affect the operation or production or generate any significant loss other than repair cost. It is a japanese philosophy that focuses upon achieving zero breakdowns and zero defects by maintaining the types of equipment throughout its. With carefully planned and scheduled maintenance, equipment is extremely well maintained. Zero breakdown strategies are designed to provide cost effective solutions to equipment problems that will allow companies to realize the maximum return on investment in their assets.
The aim of productive maintenance was to maximize plant and equipment effectiveness to achieve optimum life cycle cost of production equipment. Oee overall equipment effectiveness is a metric that identifies the percentage of planned production time that is truly productive. Action plans in implementation of total productive maintenance. It was developed in japan in the 1960s, but has been adapted over time to center on those who operate the equipment. Mar 02, 2016 total productive maintenance tpm is a system for performing proactive maintenance, with the goal of increasing equipment availability and avoiding breakdowns. It addresses the maintainability of the machine that ultimately. 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.
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