The aim of productive maintenance was to maximize plant and equipment effectiveness to achieve optimum life cycle cost of production equipment. This site is like a library, use search box in the widget to get ebook that you want. View notes total productive maintenance from ise 495 at university of southern california. Total productive maintenance philosophy and methodology r. Tpm brings maintenance into focus as a vital part of business. Total productive maintenance certification excellence. 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. Total productive maintenance tpm is a system designed to stabilize equipment performance and reliability. Total productive maintenance total productive maintenance. Total productive maintenance tpm is the process of maximizing equipment effectiveness through the active involvement of all supporting departments. Reliabilitycentred maintenance rcm originated in the aviation industry, and is focused on equipment reliability 3. This waste is due to operators, maintenance personal, process, tooling problems and nonavailability of components in.
Total productive maintenance tpm is a maintenance program which involves a newly defined concept for maintaining production plants and equipment. An introduction to total productive maintenance tpm j. A study of total productive maintenance implementation f. Introduction to total productive maintenance by seiichi nakajima. Oee measures improvements in productivity lean production. Introduction total productive maintenance tpm is a productivity improvement practice analogous to the use of total quality management tqm, 1 while 2 describes it as a japanese concept of equipment management that allows a facility to improve decisively the equipment performance in the manufacturing area with the help and involvement of. Total productive maintenance questions vskills practice. Tpm brings maintenance into focus as a necessary and vitally important part of.
The goal of the tpm program is to markedly increase production while, at the same time, increasing employee morale and job satisfaction. 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. It was developed in japan in the 1960s, but has been adapted over time to center on those who operate the equipment. 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. Total productive maintenance lean manufacturing and six. The primary goals of tpm are to eliminate waste caused by accidents, emergency and unscheduled downtime, defects and speed losses. In total productive maintenance, reliability and availability are the ultimate goals and the way to. Massachusetts institute of technology, sloan school of management, 1996, and thesis m. Implementation of total productive maintenance on haldex. Total productive maintenance tpm is best known for its use worldwide by major companies particularly in the food and chemical sectors. The goal of total productive maintenance tpm is to improve overall productivity by optimizing equipment availability. 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.
Click download or read online button to get total productive maintenance book now. Tpm means equipment is well maintained, eliminating any chance of failures. Total productive maintenance tpm is a maintenance program which involves a newly defined concept for maintaining plants and equipment. An analysis of maintenance strategies and development of a. Tpm was introduced to achieve the following objectives. The goal of the tpm program is to markedly increase production while at the same time increasing employee morale and job satisfaction. Total productive maintenance increasing efficiency. Implementing successful total productive maintenance tpm in. This came in response to the maintenance and support problems in commercial factory. The total productive maintenance tpm is a concept for maintenance activities. A few ways to help find root causes 315 the 5 whys 317 fishbone diagrams 320 fault tree diagrams 323. A strategic approach to improve the performance of maintenance activities is to effectively adapt and implement strategic tpm initiatives in the manufacturing organizations.
In all this, higher level of production effectiveness is attained in terms of cost effectiveness, safety, employee motivation, product quality, reduced defects rate and market positioning in order fulfillment 10. Lessons from the gemba volume 1 is a collection of stories and case studies about applying lss to notforprofit organizations. Total productive maintenance and the basic pillars of tpm. Introduction to total productive maintenance study guide tpm100sg00100. Implementing successful total productive maintenance tpm. How to implement a total productive maintenance plan tpm. Tpm mainly involves every individual in the organization including operator and the senior management in equipment improvement wireman, 2004. Journal of quality in maintenance engineering a case study of total productive maintenance implementation at precision tube mills i. An introduction to total productive maintenance tpm.
A study of total productive maintenance implementation. Total productive maintenance tpm is a welldefined and timetested concept for maintaining plants and equipment. This waste is due to operators, maintenance personal, process, tooling problems and nonavailability of components in time etc. As a benchmark it can be used to compare the performance of a given. Implementation of total productive maintenance and overall. Total productive maintenance increasing efficiency management. Implementing total productive maintenance at an electronic company by assoc. This is done to add value to the business organization. The third benefit is known as autonomous maintenance.
Maintenance prevention and maintainability improvement gave birth to productive maintenance. 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. Its main objective is to maintain the equipment or plant in topmost condition without disrupting the efficient flow of daily production. Study of total productive maintenance and manufacturing performance of a manufacturing industry by mr. It evolved with other maintenance practices, including preventive maintenance, into the tpm program we know today. Pdf total productive maintenance tpm implementation. Adoption of total productive maintenance practices by food. The most popular method is total productive maintenance tpm.
The start value for the thesis goals proved to be overestimated, with the actual initial value at 115 produced units per hour and employee. A total productive maintenance tpm is a medical science of machine which improves the performance of maintenance activity, product and process quality, employee morale and job satisfaction. This is a sample of the total productive maintenance training course powerpoint download. 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. Maintenance downtime is included in manufacturing scheduling, and in many cases, becomes an integral part of the manufacturing process. Often referred to as total production maintenance or total productivity maintenance, the formal name for the tmp toyota introduced is total productive maintenance.
Production losses and overall equipment effectiveness. Dale manchester school of management, umist, manchester, uk keywords total productive maintenance, implementation, organizational structure abstract this paper focuses on a study of total productive maintenance tpm in three companies. Total productive maintenance tpm is a unique approach to equipment maintenance. Total productive maintenance tpm is widely used as maintenance tool in manufacturing process and it is defined as such productive activities that are implemented by all employees. Tpm leads to reduced downtime, fewer stops and breakdowns, and a smaller likelihood that products will suffer quality defects during the manufacturing process. Dear ladys and gentleman, this is a survey about the topic total productive maintenance tpm. Total productive maintenance is an innovative approach to equipment maintenance involving maintenance personnel and operators working in teams focusing on eliminating equipment breakdowns and equipment related defects. An introduction to tpm total productive maintenance tpm is a concept for maintaining plants and equipment. Total productive maintenance download ebook pdf, epub. T r srinivas3, raghavendra m j4 1assistant professor, department of mechanical engineering, p. Importance of total productive maintenance engineering essay. This master thesis is aimed to address these issues for volvo trucks. 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 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. Use this editable professional powerpoint presentation to teach tpm and maximize equipment effectiveness. Total productive maintenance tpm is a lean manufacturing approach developed in japan in 1971. Like many other process improvement methods, tpm has grown into a general process management method which can be applied in many situations, even. 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. A methodology for implementing total productive maintenance. Total productive maintenance preventative maintenance series english and japanese edition seiichi nakajima, norman bodek on. He has developed suitable pedagogical methods for two undergraduate courses of. Total productive maintenance tpm is a maintenance program, which involves a newly defined concept for maintaining plants and equipment. Volvo is today working with maintenance in a reactive manner, where events and failures choose the direction. Effect of total productive maintenance practices on. Tpm can be considered the science of machinery health. Ahuja pankaj kumar, 2009,a case study of total productive maintenance implementation at precision tube mills, journal of quality in.
Total productive maintenance tpm why, what, where, who anand subramaniam 2. That is the method of training operators to get involved in maintenance task too. Total productive maintenance tpm originated in the assembly line industry, and is focused on improving the quality of people and processes 4. Organizations that want to compete and become world class need to successfully implement total productive maintenance tpm programs. An oee score of 100% represents perfect production. This approach uses the skills of all employees and seeks to incorporate maintenance into the everyday performance of a facility. Concept of quality, total quality management tqm, total productive maintenance tpm, statistical quality control sqc, six sigma.
The number, frequency, and severity of equipment breakdowns can be decreased with proper. Achieving 100 percent reliability takes discipline and teamwork. The goals of a tpm program are to maximize equipment productivity, maximize equipment availability and make quality product by eliminating causes of equipment defects, losses and wastes. Keep your equipment fully functional with total productive maintenance. Businesscentred maintenance originated in the process industry, and. 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. Maintenance and reliability workers are always striving for perfect.
The tpm program significantly increases labor and capital productivity while, at the same time, increases employee morale and job satisfaction. Total productive maintenance preventative maintenance series english and japanese edition. The total productive maintenance tpm powerpoint also comes with a 19 page workbook. The main objective of this research was to find the best strategy to improve the performance of tpm through the autonomous. Total maintenance system includes maintenance prevention and maintainability improvement as. Effect of total productive maintenance tpm implementation. The goal of the tpm program is to markedly increase production while, at the same. The concept of total productive maintenance tpm has been introduced and developed by japanese in 1971. Prepare for total productive maintenance from vskills to help you to boost your skills and get yourself certified in the saem. As a companywide initiative, total productive maintenance tpm maximizes the effectiveness and longevity of equipment. Introduction total productive maintenance tpm which is one of the key concepts of lean manufacturing, challenges the view that maintenance is no more than a function that operates in the background and only appears when needed. By then nippon denso had made quality circles, involving the employees participation. Oee overall equipment effectiveness is a best practices metric that identifies the percentage of planned production time that is truly productive. Total productive maintenance tpm is a maintenance concept that aims not only to improve productivity but also to improve morale and workers responsibilities to do they own job.
Total productive maintenance is a suitable method if there is complex andor expensive machinery of which the capacity is insufficient, or if the maintenance costs of those machines are racing up. Mar 24, 2018 total productive maintenance definition and objectives of total productive maintenance pillars of total productive maintenance benefits of total productive maintenance. Total productive maintenance tpm is an equipment management program that emphasizes operator involvement and ownership of equipment performance. Analysis of barriers of total productive maintenance tpm.
Tpm can be of great value and its target is to improve core business processes. 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. College of engineering, mangaluru, karnataka state, india 574153. Total productive maintenance, performance efficiency, quality rate. Pdf implementation of total productive maintenance. Time and conditionbased maintenance 299 introduction to oncondition maintenance 302 friction between maintenance and production 304 what if we were starting from scratch. However, as the uk moves more and more into capital intensive advanced manufacturing the tpm approach will pay dividends in many sectors and in firms of all sizes and mark a path to the. It is teambased preventive and productive maintenance and involves every level, from top executive to the floor operator. Gli scopi, i compiti, le attivita e le responsabilita pertinenti alle due funzioni sono generalmente ben codificati e strutturati. Total effectiveness indicates tpms pursuit of economic efficiency or profitability which includes productivity, cost, quality, delivery, safety, environment, health and morale. Eight pillars of total productive maintenance tpm 9. Aug 14, 2012 in the highly competitive environment, to be successful and to achieve worldclassmanufacturing, organizations must possess both efficient maintenance and effective manufacturing strategies. In the structure, total productive maintenance resembles many aspects of total quality management tqm, such as employee empowerment, managements commitment, longterm goal settings, etc. 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.
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 tpm focuses on keeping all equipment in top working condition to avoid breakdowns and delays in manufacturing processes. The goal of the tpm program is to markedly increase production while, at the same time, increasing employee. When equipment breaks down or performs poorly, it causes serious disruption to your business. Total productive maintenance tpm is the process of preventing premature machine deterioration by identifying issues or problems early on and immediately finding applicable means to solve it. Design of a total productive maintenance model for effective. Operations management mechanical engineering instructor name.