Since the jipm tpm awards were founded, over 3000 organizations have won awards, including unilever, wrigley, tetra pak, heineken and arcelor mittal. Total productive maintenance tpm is a methodology that aims to increase the availability of existing equipment hence reducing the need for further capital investment. The goal of any tpm program is to eliminate losses tied to equipment maintenance or, in other words, keep equipment producing only good product, as fast as possible with no unplanned downtime. The process of integrating equipment maintenance into the manufacturing process, in order to stabilize equipment, thereby increasing availability, performance and quality of the equipment. Within years tpm evolved as a management approach and spread all over the world. Methodology designed to ensure that every machine in a production process always performs its required task and its output rate is never disrupted. Clicking on the view all link below will give you additional information on each of these key tools. The two objectives of centerlining are to determine the best settings for a production process and to ensure the best settings are always used during production.
Tpm is a methodology and philosophy of strategic equipment. Total productive maintenance, preventive maintenance, overall equipment. An introduction to total productive maintenance tpm plant. 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. By now the tpm implementation activities would have reached maturity. Reliabilitycentered maintenance methodology reliabilitycentered maintenance rcm is the optimum mix of reactive, time or intervalbased, conditionbased, and proactive maintenance practices. Performing manual oee calculations helps reinforce the underlying concepts and.
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. Tpm methodology implementation, change of behaviour and culture. In addition, the longer the tpm implementation time period, the more. The define, measure, analyze, improve and control dmaic methodology aims to identify and eliminate variation in a process. Tpm staff were launching the tpm journalism fund as an additional way for readers and members to support tpm. Effectively and efficiently employ machinery, materials, methods and manpower through the use of lean six sigma tools. An introduction to total productive maintenance tpm by venkatesh j.
An introduction to total productive maintenance tpm faculty. Tps lean manufacturing tools methods 5s tpm kanban. Other areas of emphasis include minimizing machine downtime resulting from unexpected breakdowns, fully utilizing a machines capabilities, and tracking life cycle cost. According to dale, tpm is complementary to tqm and can serve as an additional driver dale, 1993. Of course there are many others, but these are the primary tools that can resolve most any manufacturing issues most all of the time. Comparing tqm with tpm the two methodologies coincide in most of their principles and strategies.
This delivers cost reductions in the organisations overheads as well as supporting improvement and sustainability of the manufacturing process efficiency. With an extended 20 years of experience, moses was previously a tpm training manager with a japaneseowned semiconductor manufacturer, silicon systems, a whollyowned subsidiary of tdk corporation, japan. Pdf quality and maintenance of manufacturing systems are closely related. Audits are a stepwise process with a progression of awards levels 5 in. Kaizen deals with the management of change and is a methodology in the right direction to improve manufacturing operations, on a continual and incremental basis following the right steps 14. This is a method in which the service life of important part is predicted based on inspection or. Tpm is a maintenance program which involves a newly defined concept for maintaining plants and equipment this paper will define tpm history, benefits, its tpm. Tpm can be of great value and its target is to improve core business processes. Especially among these, 6sigma and erp are the most figurative and energetic programs on the basis of an innovative quality in an electronic and manufacturing field most actively. Objective of tpm is to ensure zero breakdowns and improve overall equipment effectiveness oee. Total productive maintenance and the basic pillars of tpm. With this course you will be able to train anyone in your company on the proper techniques for achieving proper resolution of any type of problem, whether it be a transactional process, manufacturing issue, medical procedure, or personnel issue.
Total productive maintenance tpm originated in the assembly line industry, and is focused on improving the quality of people and processes 4. Total productive maintenance tpm is a proven methodology in manufacturing industries in all sectors process, and discrete. Since 1971 auditing and presenting awards for tpm achievement since 1991 internationally. These principal maintenance strategies, rather than being applied independently, are integrated to take advantage of their re. Centerlining is a methodology used to reduce product and process variability and increase machine efficiency in manufacturing and other industrial processes. Introduction mportance of tpm total productive maintenance liberalization of global economy has resulted tough competition in global market and for the sustainability in market for any product or service, the optimization of resources and. It blurs the distinction between the roles of production and.
The essence of research, whether basic or applied, lies in the scientific method, and much of this book deals with scientific methodology. Office tpm benefits organisations by eliminating losses in the administrative systems across the whole organisation and into the extended supply chain. The goal of the tpm program is to markedly increase production while, at the same time, increasing employee morale and job satisfaction. An introduction to total productive maintenance tpm.
If machine uptime availability is not predictable and product can not flow smoothly and reliably then there will be inventory and buffers must be kept to protect the customer. Tpm total productive maintenance, erp enterprise resource planning, etc. An introduction to total productive maintenance tpm j. For example, in a clean and wellorganized work environment, tools and parts are. The use of baseline data, information on possible strategies, resource constraints, and. The three goals of tpm are zero unplanned failures, zero product defects, and zero accidents. This section elaborates the impact analysis of tpm on various indicators such as productivity p, quality q, cost c, delivery d, safety s and morale m. Tpm guidebook chapter 2 implementation steps tpm toolbox. The japan institute of plant maintenance jipm approach to tpm the jipm definition of tpm is. Every dollar contributed goes toward expanding our editorial staff. Tpm methodology is implemented in the company in the financial year 201112. Total productive maintenance tpm is an approach to equipment maintenance that aims to achieve a perfect production process by increasing productivity, efficiency, and safety.
The difference in the techniques of basic and applied. Pioneered by the japanese firm nippondenso, a manufacturer of automotive components and. The goal of the tpm program is to markedly increase production while, at the same. Tpm total productive maintenance is a maintenance philosophy designed to integrate equipment maintenance into the manufacturing process.
Total productive maintenance tpm originated in japan in 1971 as a method for improved machine availability through better utilization of maintenance and production resources. In this chapter the focus shall be on the relationship between lean and tpm, by comparing their goals and principles as well as how lean and tpm can strengthen each others results in order to reach sustainable growth of the organization. Tpm is a critical principle for lean manufacturing. Target setting within the tpm framework is a n evidencebased and datadriven, collaborative process that.
Tpm means equipment is well maintained, eliminating any chance of failures. Thus there is an improvement have been noticed in the overall results. Total productive maintenance tpm is a maintenance program, which involves a newly defined concept for maintaining plants and equipment. Total productive maintenance tpm implementation in a machine. Pdf total productive maintenance tpm implementation in a. Use of the scientific method in applied research assures objectivity in gathering facts and testing creative ideas for alternative business strategies. Introduction the concept of total productive maintenance tpm has been introduced and developed by japanese in 1971. The differences in the japanese and western approach to defining tpm are subtle, with. In the 1970s, tpm evolved to a comprehensive system based on respect for individuals and total employee participation. Used for improving organization of the workplace, the name comes from the six steps required to implement and the words each starting with s used to describe each step. Dmaic is a structured problemsolving methodology that directs a lean.
Tpm total productive maintenance is a holistic approach to equipment maintenance that strives to achieve perfect production. As tpm manager, he led in handson tpm implementation and conducted tpm training, 5s, kaizen employee suggestion system and other tpmrelated technical skills training. Definition of 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. Next step is implementation leading to institutionalizing wherein tpm. Establish a plan to change whatever needs to be improved, carry out changes on a small scale. Total productive maintenance lean manufacturing and six.
Tdk is an advanced tpm practitioner and a recipient of the prestigious worldclass tpm award from the jipm. A approach, implementation factors, tpm pillars, correlation i. Pdf total productive maintenance tpm implementation. Technology project management various organizations tpm. Tdk is an advanced tpm practitioner and a recipient of the prestigious world. Tpm focuses on involving machine operator in the routine checks and cleaning of the machine to detect problems earlier.
Engage all employees to use effective problem solving tools to make permanent and significant reduction in plant losses. Inventory ties up cash, takes up space, and may have shelf life. The define, measure, analyze, improve and control dmaic methodology eans objective is to identify and eliminate waste in all processes. Learn about 4 phases and 12 steps of tpm implementation.
Chapter 6 impact analysis of tpm on pqcdsm indicators 6. Businesscentred maintenance originated in the process industry, and focuses on performing costeffective maintenance to achieve business goals 5. Tpm includes improvement, autonomous maintenance, quality maintenance etc. This waste is due to operators, maintenance personal, process, tooling problems and nonavailability of components in time etc. Tpm consultant provides training to selected managers, supervisors and engineers. 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. Centerlining methodology training video convergence training. Tpm improves equipment effectiveness lean production. Tpm implementation in a food industrya pdca approach. Tpm emphasizes proactive and preventative maintenance to maximize the operational efficiency of equipment.
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