Total Productive

Maintenance
Introduction to TPM
 Total Productive Maintenance (TPM) is a holistic approach to equipment maintenance that
emphasizes proactive and preventive maintenance to maximize the operational efficiency of
equipment or it 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 maintenance program which involves a newly defined
concept for maintaining plants and equipment. The goal of the TPM program is to markedly
increase production while, at the same time, increasing employee morale and job satisfaction.
 TPM brings maintenance into focus as a necessary and vitally important part of the business. It
is no longer regarded as a non-profit activity. Down time for maintenance is scheduled as a part
of the manufacturing day and, in some cases, as an integral part of the manufacturing process.
The goal is to hold emergency and unscheduled maintenance to a minimum.
Goals Of TPM

 The main goal of total productive maintenance is to improve productivity by reducing

downtime, Increase overall equipment effectiveness (OEE) over time and Some more
Goals are

 No breakdowns

 No stops or running slowly

 No defects

 No accidents

 Maximize equipment effectiveness

History Of TPM

 TPM was first developed in Japan by Seiichi Nakajima in the 1950s and first implemented
in 1960. TPM became part of Toyota’s workflow and significantly reduced equipment-
related problems, enabling the evolution of the just-in-time (JIT) strategy for production.

 In 1971 Japan Institute of Plant Maintenance (JIPM) establishes TPM framework &
expanded it to include 8 activities of TPM that required participation from all areas of
manufacturing and non-manufacturing in the concepts of lean manufacturing.
 Pillars of TPM
There are 9 Pillars of TPM & Following are those 9 Pillars
 Autonomous Maintenance
 Focused Improvement
 Planned Maintenance
 Quality Maintenance
 Early Equipment Management
 Training and Education
 TPM in Administration
 Health, Safety and Enviornment
 Energy Savings
Autonomous Maintenance
 Autonomous maintenance involves regular and preventive maintenance tasks carried out
by operators, such as lubrication, cleaning, and servicing of production lines. By assigning
operators a higher level of responsibility, you enable early identification of equipment
issues before they escalate into critical problems.
 In Autonomous Maintenance We need a skilled and well trained Operator Who Knows
About the Machinery that how it works So it can take care of it
 This gives machine operators a feeling of ownership of their equipment and increases their
knowledge of the particular piece of equipment.
 Implementing autonomous maintenance involves cleaning the machine to a "baseline"
standard that the operator must maintain. Standardization ensures everyone follows the
same procedures and processes.
7 Steps of Autonomous Maintenance

The 7 Steps of Autonomous Maintenance are as Follows

 Initial Cleaning

 Countermeasures of source of contamination & hard to reach areas

 Preparation of tentative Autonomous Maintenance Schedule

 General inspection

 Autonomous Inspection

 Standardization

 Autonomous Management
Focused Improvement

 Focused improvement is based around the Japanese term "kaizen," meaning

"improvement." In manufacturing, kaizen requires improving functions and processes
continually.
 Focused improvement activities aimed at enhancing equipment performance
 It Increases productivity, reduces cycle times, and eliminates inefficiencies
 Encourages cross-functional teamwork.
 Small group activities aimed at continuous improvement.
 Focused improvement increases efficiency by reducing product defects and the number of
processes while enhancing safety by analyzing the risks of each individual action.
Planned maintenance

 Planned maintenance involves studying metrics like failure rates and historical downtime
and then scheduling maintenance tasks based around these predicted or measured failure
rates or downtime periods
 It also Prevents unexpected failures, extends equipment life, and reduces repair costs.
 It greatly reduces the amount of unplanned downtime by allowing for most maintenance to
be planned for times when machinery is not scheduled for production.
 Its benefits include a gradual decrease in breakdowns leading to uptime and a reduction in
capital investments in equipment since it is being used to its maximum potential.
Quality maintenance
 The quality maintenance pillar focuses on working design error detection and prevention into
the production process. It does this by using root cause analysis to identify and eliminate
recurring sources of defects. By proactively detecting the source of errors or defects,
processes become more reliable, producing products with the right specifications the first
time.

 The biggest benefit of quality maintenance is it prevents defected products from moving
down the line, which could lead to a lot of rework.

 It Majorly Focuses on Enhances product quality, reduces waste, and improves customer
satisfaction.
Early equipment management

 Early equipment management leverages existing knowledge of current technology to develop

improved and more efficient machines. A better understanding of machines during operation
helps optimize performance levels and maintenance.
 It is Useful in Designing a new Technology so from this we can compare the Previous
technology and according to previous experience we can rectify it in the new technology and
it is also about the learning of new technologies before implementing it.
 It Reduces startup issues, enhances maintainability, and ensures smooth operation from the
beginning.
 Aims to reduce lifecycle costs and improve equipment reliability.
Training and Education
 To provide continuous improvement, TPM requires comprehensive training and education
to address employee skills gaps. Team members must know best practices for operation
and how to apply TPM knowledge for optimal performance.
 Training and education applies to operators, managers and maintenance personnel. They
are intended to ensure everyone is on the same page with the TPM process and to address
any knowledge gaps so TPM goals are achievable
 It Improves skills, enhances problem-solving abilities, and fosters a culture of continuous
learning.
 This is where operators learn skills to proactively maintain equipment and identify
emerging problems.
 The maintenance team learns how to implement a proactive and preventive maintenance
schedule, and managers become well-versed in TPM principles
Safety, Health, and Environment
 Maintaining a safe working environment means employees can perform their tasks in a
safe place without health risks. It's important to produce an environment that makes
production more efficient, but it should not be at the risk of an employee's safety and
health.
 It Ensures safe working conditions and environmentally friendly practices and it
eventually Reduces accidents, promotes a healthy workplace, and ensures compliance
with regulations.
 It ensures that TPM activities do not compromise safety or environmental standards and
Focus on creating a safe working environment.
 For Environment Purpose Company’s Regularly monitor all there emission or any such
Harmful things that can impact the environment or can manipulate the Environment that
can be dangerous to Eco system.
 Regular safety audits, risk assessments are carried out for Safety & Health.
TPM in Administration
 Total productive maintenance should look beyond the plant floor by addressing and eliminating
areas of waste in administrative functions. This means supporting production by improving
things like order processing, procurement and scheduling.
 Inefficiencies in these areas can lead to production delays, increased costs, and decreased
customer satisfaction.
 It Streamlines processes, reduces administrative waste, and supports overall TPM goals.
 if order-processing procedures become more streamlined, then material gets to the plant floor
quicker and with fewer errors, eliminating potential downtime while missing parts are tracked
down.
Energy Savings
 We implement energy saving practices within the TPM framework to enhance
sustainability and reduce costs.
 We can reduce energy consumption in TPM by optimizing equipment efficiency,
conducting regular maintenance, and upgrading to energy-efficient technologies.
Implement energy management systems, train employees on conservation practices, and
establish shutdown procedures for idle equipment.
 Align production schedules with energy demand, conduct regular energy audits, and adopt
technologies like VFDs and energy-efficient HVAC systems.
Conclusion
 Total Productive Maintenance is a holistic approach that involves all employees in proactive
maintenance activities. Its goal is to achieve perfect production by maximizing equipment
effectiveness and fostering a culture of continuous improvement.
 By implementing TPM, companies can achieve higher efficiency, better product quality, and
improved employee engagement.
 The Benefits of TPM are- Increased Equipment Availability, Cost Savings, Enhanced
Morale, Continuous Improvement, Improved Product Quality & Safe working Environment.
 TPM is a Team Plan that's why Implementing TPM requires commitment from all levels of
the organization, especially leadership. The transition may come with challenges, but the
long-term benefits of enhanced efficiency, reduced costs, and improved quality make it a
worthwhile investment.