Dr.

Chaminda Karunasena
Senior Lecturer, Dept. of Mechanical & Manufacturing Engineering,
Faculty of Engineering, University of Ruhuna.
E-mail : chaminda@mme.ruh.ac.lk
Web : http://www.eng.ruh.ac.lk/mme/
LinkedIn : https://www.linkedin.com/in/chamindakarunasena
 Basic Understanding On Maintenance Management And
Maintenance Dept. Activities
 Different Types Of Maintenance Techniques Available
 Maintenance KPIs
 Standard Maintenance Analysis Techniques
 Maintenance Communication Systems
 Introduction To Autonomous Maintenance
 Introduction To TPM
 Approach Of Improving An Existing Plant Maintenance
System
 Concept Of KAIZEN
 Non Destructive Testing Techniques
 Introduction To 5S Concept
 Introduction To ISO Quality System

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https://www.youtube.com/watch?v=nb031_LQIHQ 3 of 13
 In any plant with any level of technology, the
maintenance role highly depends on human
resource
 So, TPM uses a philosophy developed to have a
productive maintenance program based on this
human recourse
 TPM origins from more human oriented approaches
for quality improvement and waste elimination in
production plants such as:
 Total Quality Management (TQM)
 Just-In-Time (JIT) Production Management
 Main TPM Tools:
 Employee empowerment
 Benchmarking/following good practices
 Effective documentation and data leads people’s decision
making

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  “TPM is a plant improvement methodology
which enables continuous and rapid
improvement through use of employee
involvement, employee empowerment, and
closed-loop measurement of results.”
“I operate,
We all are
“I fix, you
you fix” design”
responsible for our
machines, our plant
and our FUTURE
“I design,
you operate”

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 Bringing maintenance role forward as a part of the
production process
 Minimize/eliminate unscheduled breakdowns
 Maximize equipment effectiveness
 Establishing a in-depth system of Preventive
Maintenance
 Involve every single employee in the organization
for the maintenance program
 Empower people to propose and initiate corrective
actions
 Reduce manufacturing cost
 Develop cross functional teams to builds positive
links between production and maintenance
departments as well as to improve productivity

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 Zero accidents

 Minimum life cycle cost

 Zero unplanned down time

 Zero speed losses

 Zero defects

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 Training and Skill
Development

Early Equipment
Management and
Maintenance Prevention
Design

Maintenance Process
Improvement
TPM

Systematic Equipment
Improvement
Cross Functional Team Based Improvements

Autonomous Maintenance
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 Research and development in total productive
maintenance (TPM) technologies
 Promoting the spread of TPM technologies
 Collection and dissemination of information and
materials about TPM technologies
 Exchange of information with various
organizations, both in Japan and abroad,
regarding TPM technologies
 Presenting awards for achievement in TPM
technology
 Authorize TPM assessment agencies world wide

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https://www.jipm.or.jp/en/activity/pm/2018/pdf/190129_01.pdf 10 of 13
 Local companies
 Unilever Sri Lanka Limited
 Premium Exports Ceylon Limited
 BRANDIX
 Etc.

 Overseas companies
 Allen Bradley
 Ford Motors
 Bajaj Auto Limited
 Kodak
 Texas Instruments
 Etc.

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 Lack of ownership, support and understanding
of the top management
 Insufficient training both in fundamentals as
well as practices
 Lack of internalizing in all levels
 Insufficient time span given for nurturing and
evolving of TPM
 Not been determined to keep going
 Unfitting personal values and social behaviours
among organizational members and TPM
coordinators

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 http://www.tvss.net/pm/tpm.htm
 http://www.tvss.net/pm/tpm.htm
 www.productivityinc.com/.../EN_Introduction_to_TPM_-_Objectives_and_Benefits.pdf
 http://www.dla.mil/do/online/eeo/eeo.htm
 http://www.authorstream.com/Presentation/livycat-204365-tpm-science-technology-ppt-
powerpoint/
 http://www.jipm.or.jp/en/company/index.html
 https://www.youtube.com/watch?v=nb031_LQIHQ

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