TOTAL PRODUCTIVE

MAINTENANCE
MAINTENANCE DEVELOPMENT

Breakdown Maintenance
Preventive Maintenance
Productive Maintenance
Total Productive Maintenance
PRODUCTIVE MAINTENANCE

UNTIL AFTER WORLD WAR II (1950S)

MECHANICAL DEVELOPMENT WAS LIMITED

DOWNTIME WAS NOT A PROBLEM;

BREAKDOWN PREVENTION WAS NOT A PRIORITY

SIMPLE TECHNOLOGY AND BUILT TO LAST
PRINCIPLE OCCURRED

NEEDS FOR MAINTENANCE SKILL WAS RARELY

HAPPEN
'PRODUCTIVE MAINTENANCE' CAME INTO EXISTENCE.

AWARENESS CREATED A SYSTEM OF REGULAR

CHECK ON A DAY TO DAY BASIS LIKE CHECKING
UP THE TIGHTNESS OF THE NUTS, BOLTS,
LEAKAGES ETC.

THIS CAUSED 'MAINTAINABILITY IMPROVEMENT'.

PREVENTIVE MAINTENANCE AND
MAINTAINABILITY IMPROVEMENT HELPS TO BRING
MAINTENANCE PREVENTION' I.E., CONSIDERABLE
REDUCTION IN MAINTENANCE ACTIVITIES.
 TOTAL PRODUCTIVE MAINTENANCE

JAPAN ADOPTED PREVENTIVE MAINTENANCE AND

PRODUCTIVITY MAINTENANCE IN THEIR PLANTS.

SEIICHI NAKAJIMA IN 1971 MADE PRODUCTIVE

MAINTENANCE AS TOTAL PRODUCTIVE
MAINTENANCE.

IF QUALITY CAN BE RESPONSIBILITIES OF THE

ROCESS CONTROL PEOPLE, WHY NOT THE MACHINE
THEY USE ALSO?

 TOTAL PRODUCTIVE MAINTENANCE

HE CREATED A COMPREHENSIVE SYSTEM WHEREIN

AUTONOMOUS MAINTENANCE BECAME AN
INTEGRAL PART OF PRODUCTIVE MAINTENANCE
SYSTEM.

TPM IS ACHIEVING PM EFFICIENCIES THROUGH

COMPREHENSIVE SYSTEM BASED ON RESPECT
FOR INDIVIDUALS AND TOTAL EMPLOYEE
PARTICIPATION AND IT BROUGHT IN AUTONOMOUS
MAINTENANCE IN TO THE SYSTEM.
 SEIICHI NAKAJIMA OFFERED CONCEPT OF TPM IN
1972 (JAPAN) AFTER STUDYING BY VISITING MANY
EUROPEAN AND AMERICAN MANUFACTURERS FROM
60S (1962)

WORKERS PRODUCTIVITY INCREASED BY 60%

ACCIDENTAL BREAKDOWN REDUCED UP TO
1/100 1/500

Close to zero

Parlor factory
PARLOR FACTORY : ZASHIKI PART OF JAPANESE
HOME WHERE THEY ENTERTAIN
THEIR GUESTS (IT KEEPS IMMACULATELY CLEAN)
 AIMS AT BUILDING UP A CORPORATE CULTURE THAT
THOROUGHLY PURSUES PRODUCTION SYSTEM EFFICIENCY
IMPROVEMENT (OEE : OVERALL EQUIPMENT EFFICIENCY)

CONSTRUCTS A SYSTEM TO PREVENT EVERY KIND OF LOSS, FOR

EXAMPLE, TO ACHIEVE ZERO ACCIDENTS, ZERO DEFECTS AND ZERO
FAILURES BASED ON GEMBA (ACTUAL SITE) AND GENBUTSU (ACTUAL
THING) OVER THE ENTIRE LIFE CYCLE OF A PRODUCTION SYSTEM.

COVERS ALL DEPARTMENTS INCLUDING PRODUCTION, DEVELOPMENT,

MARKETING, AND ADMINISTRATION.

REQUIRES ALL AND FULL INVOLVEMENT FROM TOP MANAGEMENT

TO FRONTLINE EMPLOYEES.

ACHIEVES ZERO LOSSES BY OVERLAPPING SMALL-GROUP ACTIVITIES.

TPM CAN BE CONSIDERED AS THE MEDICAL
SCIENCES OF MACHINES

Employee morale
Increase production
Job satisfaction

BRINGS MAINTENANCE INTO FOCUS AS NECESSARY

AND VITALLY IMPORTANT PART OF THE BUSINESS;
NO LONGER REGARDED AS A NON-PROFIT ACTIVITY
 COMPUTERIZED MAINTENANCE
MANAGEMENT SYSTEMS (CMMS)

CMMS IS SOFTWARE THAT IS USED TO SCHEDULE AND

RECORD OPERATION AND PREVENTIVE/PLANNED
MAINTENANCE ACTIVITIES ASSOCIATED WITH FACILITY
EQUIPMENT.

THE CMMS CAN GENERATE AND PRIORITIZE WORK ORDERS

AND SCHEDULES FOR STAFF TO SUPPORT "TROUBLE"
CALLS AND TO PERFORM PERIODIC/PLANNED EQUIPMENT
MAINTENANCE.
 COMPUTERIZED MAINTENANCE
MANAGEMENT SYSTEMS (CMMS)
UPON COMPLETION OF A WORK ORDER, PERFORMANCE
INFORMATION, SUCH AS THE DATE WORK WAS PERFORMED,
SUPPLIES/INVENTORY, AND MANHOURS EXPENDED,
TYPICALLY IS LOADED INTO THE DATABASE FOR TRACKING,
TO SUPPORT FUTURE OPERATIONS/PLANNING.

CMMS ARE USED BY FACILITIES MAINTENANCE

ORGANIZATIONS TO RECORD, MANAGE, AND COMMUNICATE
THEIR DAY-TO-DAY OPERATIONS. THE SYSTEM CAN PROVIDE
REPORTS USED IN MANAGING THE ORGANIZATION'S
RESOURCES, PREPARING FACILITIES METRICS TO USE IN
EVALUATING THE EFFECTIVENESS OF THE CURRENT
OPERATIONS, AND FOR MAKING
ORGANIZATIONAL AND PERSONNEL DECISIONS.
 COMPUTERIZED MAINTENANCE
MANAGEMENT SYSTEMS (CMMS)
IN TODAY'S MAINTENANCE WORLD, THE CMMS IS AN
ESSENTIAL TOOL FOR RECORDING WORK REQUIREMENTS,
TRACKING THE STATUS OF THE WORK, AND ANALYZING THE
RECORDED DATA IN ORDER TO MANAGE THE WORK,
PRODUCE REPORTS, AND HELP CONTROL COSTS.

FACILITY PROFESSIONALS USE TOOLS TO MANAGE THE

PLANNING AND DAY-TO-DAY OPERATIONS AND
MAINTENANCE ACTIVITIES REQUIRED FOR A SINGLE
FACILITY OR A LARGE COMPLEX.

THESE TOOLS ALSO PROVIDE ALL OF THE INFORMATION

REQUIRED TO MANAGE THE WORK, THE WORK
FORCE, AND THE COSTS NECESSARY TO GENERATE
MANAGEMENT REPORTS AND HISTORICAL DATA.
 COMPUTERIZED MAINTENANCE
MANAGEMENT SYSTEMS (CMMS)

A MODERN CMMS MEETS ALL THESE REQUIREMENTS

AND ASSISTS THE FACILITIES MAINTENANCE MANAGER
WITH WORK RECEPTION, PLANNING, CONTROL,
PERFORMANCE, EVALUATION, AND REPORTING.

SUCH A SYSTEM WILL ALSO MAINTAIN HISTORICAL

INFORMATION FOR MANAGEMENT USE. THE MANAGER
SHOULD EVALUATE MANAGEMENT DATA REQUIREMENTS
AND ESTABLISH ELECTRONIC DATA NEEDS PRIOR TO
ACQUIRING A NEW CMMS OR ADDITIONS
TO/REPLACEMENT OF AN EXISTING SYSTEM.

 COMPUTERIZED MAINTENANCE
MANAGEMENT SYSTEMS (CMMS)

THE EVALUATION SHOULD INCLUDE AN ANALYSIS

BEFORE INVESTING IN ADDITIONAL OR NEW CMMS
CAPABILITIES. THE MANAGER SHOULD ONLY ACQUIRE
WHAT IS NECESSARY TO ACCOMPLISH THE
MAINTENANCE ORGANIZATION'S GOALS.
THIS IS THE END OF LECTURE.
ANY QUERY OR POINT OF
INTEREST ABOUT THIS
LECTURE

YOUR QUERIES ARE ALWAYS

WELCOMED
 ASSIGNMENT NO. 1

ONE OF THE MAIN OBJECTIVES OF

MAINTENANCE IS TO MAXIMIZE THE
UTILIZATION OF AVAILABLE RESOURCES.
ELABORATE HOW CAN THIS OBJECTIVE OF
MAINTENACE BE ACHIEVED IN AN
ORGANIZATION?