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. A planned maintenance program leverages historical downtime data and predictive analytics to schedule key maintenance tasks around. Pdf total productive maintenance download ebook for free. Use this editable professional powerpoint presentation to teach tpm and maximize equipment effectiveness. It is teambased preventive and productive maintenance and involves every level, from top executive to the floor operator. Performance speed loss ideal cycle time operating time total pieces quality quality loss good pieces total pieces oee availability x performance x quality. Total productive maintenance and the basic pillars of tpm.
Pdf total productive maintenance implementation procedures. Total productive maintenance usually focusses on one piece of equipment or plant area at a time on the following losses of production and breakdowns. The word total in total productive maintenance is common to. The number, frequency, and severity of equipment breakdowns can be decreased with proper. Mantenimiento productivo total tpm ingenieria industrial. Implementing successful total productive maintenance tpm. Maintenance prevention and maintainability improvement gave birth to productive maintenance. Total productive maintenance tpm is a unique approach to equipment maintenance. The goal of the tpm program is to markedly increase production while, at the same time, increasing employee morale and job satisfaction. The human resource aspect was investigated to assess motivation of operators through training to reduce set up times, change over stoppages, defects rate and resource wastage on the shop floor. Total productive maintenance is a complete system for maintenance of equipment that aims at achieving an optimal production environment devoid of defects, downtime, stoppages and accidents.
Total productive maintenance tpm is the process of maximizing equipment effectiveness through the active involvement of all supporting departments. All books are in clear copy here, and all files are secure so dont worry about it. 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. Pdf base principles and practices for implementation of. Tpm leads to reduced downtime, fewer stops and breakdowns, and a smaller likelihood that products will suffer quality defects during the manufacturing process. Maintenance cm, preventive maintenance pm or total productive maintenance tpm have allowed extra solutions to a process planning problem faced by company in comparison to the conventional firefighting syndrome. Total productive maintenance implementation procedures in manufacturing organizations using ad principles the seventh international conference on axiomatic design worcester june 2728, 20. Total productive maintenance tpm is a system designed to stabilize equipment performance and reliability. Process performance, such as the ratio of achieved to planned work, as well as of schedule compliance. Lack of understanding of the method and implementation guidelines appear to be the major factors.
The process of integrating equipment maintenance into the manufacturing process, in order to stabilize equipment. Audit, schedule a periodic audit first daily, then weekly to verify that the 5s. This experience led to the recognition that a leadership mindset engaging front line teams in small group improvement activity is an essential element of. Tpm permanently improves the overall effectiveness of equipment, with the active involvement of operators. 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. Oee is a metric to evaluate the effectiveness of your tpm improvements. First published in japan by asian productivity organization leaf square hongo building 2f 1241 hongo, bunkyoku tokyo 1033, japan. Action plans in implementation of total productive maintenance.
Adoption of total productive maintenance practices by food. 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. Total productive maintenance tpm concepts and literature. Recent advancements in information systems and computer technology have led to developments in equipment and robotic technology that have permanently changed the characteristics of manufacturing equipment. Identify and prevent costly equipment breakdowns before they occur with tpm. Total productive maintenance, strategic management, books.
Tpm total productive maintenance tpm is for improving productivity by making processes more reliable and less wasteful. By then nippon denso had made quality circles, involving the employees participation. 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. Total productive maintenance universitas brawijaya. This waste is due to operators, maintenance personal, process, tooling problems and. Keep your equipment fully functional with total productive maintenance. The total productive maintenance tpm is a concept for maintenance activities. Total productive maintenance implementation procedures in manufacturing organizations using axiomatic design principles conference paper pdf available june 20 with 3,984 reads how we. This main purpose of this study was to focus on developing a framework of maintenance strategy as guidelines for.
Total productive maintenance tpm implementation in a. Total productive maintenance tpm programs result in safer workplaces, increased quality. From an empirical study, conducted by these authors, it is revealed that demanding quality in maintenance practices is still a far cry. Total productive maintenance tpm i hadnt really intended to introduce total productive maintenance tpm, in fact i didnt even know thats what it was at that time, it simply happened as a byproduct of another project recounts paul wilson, managing director of aster training about his. Secara berkesinambungan meningkatkan semua kondisi operasional dalam sebuah sistem produksi dengan cara menstimulasi daily awareness dari semua karyawan. Time and conditionbased maintenance 299 introduction to oncondition maintenance 302 friction between maintenance and production 304 what if we were starting from scratch. By giving ownership and responsibility of equipment and processes to the right employees, equipment breakdowns are reduced. Productive maintenance tpm implementation on an organization in terms of productivity and quality levels. 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. This paper presents a brief action plan for implementation of total productive maintenance tpm. This means that equipment is predictable to have zero failures, slow runs, or defects.
The concept of total productive maintenance tpm has been introduced and developed by japanese in 1971. Total productive maintenance program perawatan yang melibatkan semua pihak yang terdapat dalam suatu perusahaan untuk dapat saling bekerja sama dalam menghilangkan break down, mengurangi waktu down time, memaksimalkan utilitas, kegiatan produksi serta kualitas dari produk yang dihasilkan. The author also provides a wealth of practical casestudies, and action plans for solving everyday. An introduction to total productive maintenance faculty.
This waste is due to operators, maintenance personal, process, tooling problems and nonavailability of components in time etc. This quiz module will test your knowledge in a multiplechoice format. Nakajima, 1988, introduction to total productive maintenance, productivity press, cambridge, ma 2 i. Total productive maintenance training tpm training online. Total productive maintenance preventative maintenance series by seiichi nakajima pdf, epub ebook d0wnl0ad this was the first book in english on total productive maintenance tpm a system which has been shown to reduce breakdowns to almost zero and increase worker productivity by as much as 150 percent. Total productive maintenance tpm portuguese definitions and terms. To enable total productive maintenance, use a cmms solution.
Download when practiced appropriately, total productive maintenance tpm can tilt the playing field in your companys favor. Reduce or eliminate costly downtime short on teory and long on practice, this book provides examples and case studies, designed to provide maintenance engineers and supervisors with a framework for operational strategies and daytoday management and training techniques that will keep their equipment. Gli scopi, i compiti, le attivita e le responsabilita pertinenti alle due funzioni sono generalmente ben codificati e strutturati. Total productive maintenance steve borris download. An introduction to total productive maintenance tpm. It was developed in japan in the 1960s, but has been adapted over time to center on those who operate the equipment. Total productive maintenance atau tpm adalah salah satu metode proses maintenance yang dikembangkan untuk meningkatkan produktifitas di area kerja, dengan cara membuat proses tersebut. This resultsoriented guide is the culmination of thirty years. The goal of total productive maintenance tpm is to improve overall productivity by optimizing equipment availability. In order to pass this course you must achieve a score higher than 80%. Tpm emphasizes proactive and preventative maintenance to maximize the operational efficiency of equipment.
A wellconceived action plan is a prerequisite to unearth those potential treasures. Total productive maintenance lean manufacturing and six. It makes similar machines turn out significantly more product lowering capital costs, with less scrap or waste lowering raw material costs, more efficiently lowers labor needed. Base principles and practices for implementation of total productive maintenance in automotive industry article pdf available in quality innovation prosperity 231. Lean, six sigma, business process reengineering, etc. Pdf total productive maintenance tpm has become one of the most popular. Tpm total productive maintenance engages operators to improve equipment. T r srinivas3, raghavendra m j4 1assistant professor, department of mechanical engineering, p. To achieve this objective, preventive and predictive maintenance is required. College of engineering, mangaluru, karnataka state, india 574153. Total productive maintenance 1 day handson workshops. 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. It blurs the distinction between the roles of production and. The aim of productive maintenance was to maximize plant and equipment effectiveness to achieve optimum life cycle cost of production 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. Effect of total productive maintenance tpm implementation. Here, di downtime for a month and n total number of months. Total productive maintenance tpm is a maintenance program which involves a newly defined concept for maintaining plants and equipment. Tpm total productive maintenance is a holistic approach to equipment maintenance that strives to achieve perfect production. Total productive maintenance tpm was first defined in 1971 by the japan institute of plant maintenance jipm. Share your top three reasons why tpm initiatives fail to me, these are the most dangerous threats to eventually mine tpm project. Total productive maintenance tpm is an equipment management program that emphasizes operator involvement and ownership of equipment performance. One distinct advantage of total productive maintenance is that it empowers the shop floor to work in a concerted manner to ensure that machines are.
The goal of the tpm program is to markedly increase production while, at the same. Read online an introduction to total productive maintenance tpm book pdf free download link book now. Tpm depends on 5s, oee, 8 pillars, autonomous and planned maintenance. A few ways to help find root causes 315 the 5 whys 317 fishbone diagrams 320 fault tree diagrams 323.
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. Top three reasons why tpm total productive maintenance. Total productive maintenance tpm, overall equipment efficiency. Currently no workshops planned, but you can use this form to register your interest and get first notification you can also visit our main tpm section with videos, case studies and white papers on everything you need to know about this very important subject our total productive maintenance workshops are hosted leading.
Total productive maintenance reliability engineering. Tpm can be of great value and its target is to improve core business processes. This approach uses the skills of all employees and seeks to incorporate maintenance into the everyday performance of a facility. Arranged in a logical, userfriendly format, total productive maintenance shows readers how to define and evaluate their existing programs and integrate them with reliability centered maintenance and time and condition based maintenance. Pdf assessment of total productive maintenance implementation. How to implement a total productive maintenance plan tpm. Total productive maintenance tpm is a maintenance program, which involves a newly defined concept for maintaining plants and equipment. Score 100% and receive an excellence badge for this course. In the structure, total productive maintenance resembles many aspects of total quality management tqm, such as employee empowerment, managements commitment, longterm goal settings, etc. The maintenance team learns how to implement a proactive and preventive maintenance schedule, and managers become wellversed in tpm principles.
Introduction to total productive maintenance study guide tpm100sg00100. The examples below are for an ore processing plant at a mine siteunscheduled maintenance downtime breakdowns example. Total productive maintenance workshop s a partners. Mengenal total productive maintenance tpm sebagai metode. Total productive maintenance tpm was developed by seiichi nakajima based on the experience of the practical application of maintenance best practices in japan between 1950 and 1970. The views expressed in this publication do not necessarily reflect the official views of the asian. This is done to add value to the business organization. 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. Total productive maintenance templates to drive tpm forward. Implementing successful total productive maintenance tpm in. Mar 28, 2017 total productive maintenance tpm is a companywide equipment maintenance system involving all employeesfrom top management to production line workers and the building custodians.
The objective of tpm is to maintain the plant or equipment in good condition. Tpm pillarseight pillars of total productive maintenance. Total productive maintenance tpm focuses on getting managers, maintenance personnel and equipment users all working together to prevent equipment problems and reduce expenditures. Total productive maintenance tpm why, what, where, who anand subramaniam 2. Unexpected breakdown of a bearing on the drive motor of the jaw crusher. This came in response to the maintenance and support problems in commercial factory. 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. The primary goals of tpm are to eliminate waste caused by accidents, emergency and unscheduled downtime, defects and speed losses. Sample of powerpoint in pdf format for tpm total productive maintenance course. This paper presents a brief action plan for implementation. Total equipment effectiveness in pursuit of profitability, not simply maintenance cost. Productivity and reliabilitybased maintenance management. A new alternative to total productive maintenance tpm.
The number, frequency, and severity of equipment breakdowns can be decreased with proper maintenance. Tpm is used by various industries, but works especially well for manufacturersand it can deliver compelling results over time. Download an introduction to total productive maintenance tpm book pdf free download link or read online here in pdf. Cayman systems usa 5 7773394 1998 revision a 980810 tpm awareness information 2 courtesy, in part, of motorola sps. When equipment breaks down or performs poorly, it causes serious disruption to your business. Maintenance and reliability workers are always striving for perfect. Tpm improves equipment effectiveness lean production. Total productive maintenance also promotes a safe working atmosphere with a zero accident strategy. Basics of total productive maintenance reliabilitylink. 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. Today, a productive maintenance strategy and programs have utmost importance in order to discover the useable but hidden resources in an organization. An introduction to total productive maintenance tpm j. A methodology for implementing total productive maintenance in.
Total productive maintenance tpm is an allinclusive method to equipment maintenance that attempts to attain flawless production zero defects. Pdf an introduction to total productive maintenance tpm. This powerpoint will help you to investigate if the introduction of tpm will help you reduce lost time on operating equipment to a tune of 30% or better. Pdf total productive maintenance tpm implementation practice.
782 49 217 383 1564 994 1449 1209 626 1027 224 665 1054 1483 874 1486 354 512 1510 1333 1383 414 833 399 995 618 59 1042 944 735 593 481 821 846