Doug kiss is a senior management consultant with tbm consulting group with over 30 years manufacturing experience, leads the tbm lean energy practice. Case study of a chemical manufacturing company bupe. Total productive management system was applied for rationalization of heat economy in a brewery. 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. Easily track the progress of maintenance requests using the kanban view. Implementing successful total productive maintenance tpm. Mar 02, 2016 total productive maintenance tpm is a system for performing proactive maintenance, with the goal of increasing equipment availability and avoiding breakdowns. Oct 22, 2016 total productive maintenance, also known as tpm, is a proactive equipment maintenance program that has always been a part of lean manufacturing. An introduction to total productive maintenance tpm by venkatesh j. Tpm total productive maintenance lean manufacturing. Overview of total productive maintenance tpm the acronym tpm or total productive maintenance is widely used in many industries especially those involve the use of equipment. This came in response to the maintenance and support problems in commercial factory. T r srinivas3, raghavendra m j4 1assistant professor, department of mechanical engineering, p. Maintenance steven borris mcgrawhill new york chicago san francisco lisbon london madrid mexico city milan new delhi san juan seoul singapore sydney toronto.
Jul 01, 20 the function of maintenance is to find, preserve, and expand manufacturing capacity. 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. Goals and features of total productive maintenance tpm. Total productive maintenance 1 is a productivity management system. This concept was first introduced by ms nippon denso co. Odoo computes standard statistics to help you plan preventive maintenance, including mean time between failure mtbf, mean time to repair mttr, and expected next failure date, and lets you automate. S t s y a next generation manufacturing success strategy. Pdf total productive maintenance implementation procedures. Total productive maintenance means the daily care and attention given to productive equipment in order to ensure they are in good working condition, operate maximally and last longer. The tpm program significantly increases labor and capital productivity while, at the same time, increases employee morale and job satisfaction.
Total productive maintenance encyklopedia zarzadzania. Total productive maintenance tpm program increases. Total productive maintenance tpm concentrates on productivity improvement, primarily by way of maximizing the availability of equipment. Your team will love using the fast and easy draganddrop interface to organize maintenance requests. Total productive maintenance tpm is a unique approach to equipment maintenance. The 1day tpm training course presentation powerpoint ppt is used by. An introduction to tpm total productive maintenance tpm is a concept for maintaining plants and equipment. 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.
Manufacturing plants are exposed to newer and rapidly changing paradigms. Total productivity maintenance and performance of selected. Total productive maintenance 1 day handson workshops. Iess 2015 design of a total productive maintenance model for effective implementation. To do that, small multidisciplinary teams improve stepbystep the overall equipment effectiveness of their production lines. You fix it, notes dave terres, corporate totalproductivemaintenance tpm coordinator for cold spring granite, one of the worlds largest producers of dimensional granite. The three goals of tpm are zero unplanned failures, zero product defects, and zero accidents. 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, also known as tpm, is a proactive equipment maintenance program that has always been a part of lean manufacturing. As a companywide initiative, total productive maintenance tpm maximizes the effectiveness of equipment. He has been certified in total productive maintenance by the japan institute of plant. Total productive maintenance is a maintenance philosophy, but there are tangible kpis that accompany it. Total productive maintenance tpm does not have a great reputation in american industry these days. The objective of tpm is to maintain the plant or equipment in good condition. Design of a total productive maintenance model for effective implementation. Machine operators take far greater responsibility for their machines upkeep. Action plans for implementation of total productive maintenance shamsuddin ahmed and masjuki hj hassan faculty of engineering, university of malaya, malaysia abstract maintenance is an inevitable function in manufacturing plants. Tpm ppt, tpm training powerpoint presentation, total. Elecon group of companies and ferromatik milacron india pvt. Thats where total productive maintenance tpm can help. Stabilised process equipment performance to reduce unplanned events and waste.
View the total productive maintenance ppt and learn what you need for successful operator driven reliability through total productive maintenance. Total productive maintenance tpm is a system for performing proactive maintenance, with the goal of increasing equipment availability and avoiding breakdowns. Tpm means equipment is well maintained, eliminating any chance of failures. It is teambased preventive and productive maintenance and involves every level, from top executive to the floor operator. Total productive maintenance second edition by terry wireman 2004, 224pp, illus. An introduction to total productive maintenance tpm. Mohideen khan born 1947, minister for environment in the tamil nadu state of india. Automate preventive maintenance to keep your line running. The pillars of tpm tpm and lean manufacturing tpm basic, use, and ideal conditions tpm analyzing and categorizing the failure data fault analysis. Tpm focuses on involving all employees in the organization. Maintenance prevention and maintainability improvement gave birth to productive maintenance. 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. Later the method was further developed by the japan institute for plant.
Use the maintenance calendar to organize and plan activities. The total productive maintenance tpm is a concept for maintenance activities. This removes the ageold philosophy that says, i run it. Related work schmidt, s, proposed a work on total productive maintenance tpm and change over reduction engineering core are fundamental parts of the. The introduction of tpm contributed to the decrease of the line failure. Factory managers want highperforming machines that never break down and switch easily from one product to another.
This article explains the total productive maintenance tpm in a practical way. College of engineering, mangaluru, karnataka state, india 574153. Maintenance must improve its ability to improve the value adding capability by delivering. Following a leanbased assessment of production processes by the facilitys continuous improvement leaders, the mill undertook the implementation of a total productive maintenance tpm process. Our goal was for workers to see the maintenance of critical equipment through a different lens. The process of integrating equipment maintenance into the manufacturing process, in order to stabilize equipment, thereby increasing availability, performance and quality of the equipment. It was developed in japan in the 1960s, but has been adapted over time to center on those who operate the equipment. Total quality management and kaizen principles in lean management. Tpm total productive maintenance tpm is for improving productivity by making processes more reliable and less wasteful. This waste is due to operators, maintenance personal, process, tooling problems and nonavailability of components in time etc. Total productive management tpm just in time production jit total employee involvement tei continuous quality improvement cqi i. This waste is due to operators, maintenance personal, process, tooling problems and nonavailability of components in. Tpm is defined as a management approach to maintenance that imports total quality management tqm philosophy and techniques to maintenance.
Discover the vital issues that you need to know to prepare for tpm introduction in this tpm powerpoint presentation. To achieve this objective, preventive and predictive maintenance is required. Total productive maintenance tpm is an approach to equipment maintenance that aims to achieve a perfect production process by increasing productivity, efficiency, and safety. Total productive maintenance total productive maintenance. In the structure, total productive maintenance resembles many aspects of total quality management tqm, such as employee empowerment, managements commitment, longterm goal settings, etc.
Search careerbuilder for total productive maintenance tpm jobs and browse our platform. Mwanzaa, charles mbohwaa a faculty of engineering and the built environment, university of johannesburg, johannesburg. The aim of productive maintenance was to maximize plant and equipment effectiveness to achieve optimum life cycle cost of production equipment. The objective of total productive maintenance is to ensure all equipment is in top working condition to avoid breakdowns and delays in manufacturing processes. Total productive maintenance tpm concepts and literature. 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. Total productive maintenance tpm is a lean tool that enables to use the equipment. Total productive maintenance tpm is one of the world class manufacturing tools that seeks to manage assets by involving everyone in the manufacturing organization. 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. It started being applied in six sigma slowly but steadily, and now is widely used as six sigma control phase tool. After reading you will understand the basics of this powerful quality and process management method what is total productive maintenance tpm. Effect of total productive maintenance tpm implementation. W artykule przedstawiono istote total productive maintenance tpm jako kompleksowego podejscia do utrzymania ruchu w.
Bhadsury 20 defined tpm as an approach to maintenance that optimizes equipment effectiveness, eliminates breakdown and. This course is meant for managers and engineers who are either planning to introduce or looking to further develop and enhance this comprehensive and people orientated approach to the achievement of world class levels of maintenance and operating performance. The aim of the study is an assessment of the amoeba management system ams. Total productive maintenance operational excellence. Total productive maintenance tpm jest to kompleksowe podejscie do utrzymania maszyn w najwyzszej. Action plans in implementation of total productive maintenance. Total productive maintenancetpm has been viewed differently by different people, but what remains constant in their definitions is the fact that tpm involves everybody in the organization and it is proactive in nature venkatesh, 2006. Design of a total productive maintenance model for. Zastosowanie systemu total productive management do. Tpm was first applied by the japanese company nippondenso. Time and conditionbased maintenance 299 introduction to oncondition maintenance 302 friction between maintenance and production 304 what if we were starting from scratch. Total productive maintenance ceopedia management online. Total productive maitenance to zarzadzanie parkiem maszyn i urzadzen wlaczajacy. The concept of total productive maintenance tpm has been introduced and developed by japanese in 1971.
Motivation of this study is to develop a proper and practicable software project real time total productive. Total productive maintenance, an equipment maintenance program technology park malaysia, a research and development centre t. Total productive maintenance tpm is a comprehensive approach to maintaining machines in the highest. Total productive maintenance training tpm training online. Complete selection of total productive maintenance products. Tpm is used by various industries, but works especially well for manufacturersand it can deliver compelling results over time. Almost all industrial production processes are carried out with the aid of machines, as a result of which each productionoriented organization is largely dependent on. One of the most important measurements of total productive maintenance is overall equipment effectiveness oee, which measures availability, performance efficiency, and quality. Equipment and tools are literally put on proactive maintenance schedules to keep them running efficiently and with greatly reduced downtime. Total productive maintenance is an innovative approach to maintenance that optimizes equipment effectiveness, eliminates. Jun 21, 20 as a companywide initiative, total productive maintenance tpm maximizes the effectiveness of equipment. Total productive maintenance and the basic pillars of tpm.
Total productive maintenance tpm tpm is a powerful program for planning and achieving minimal machine downtime. A few ways to help find root causes 315 the 5 whys 317 fishbone diagrams 320 fault tree diagrams 323. The aim of productive maintenance was to maximize plant and equipment. Total productive maintenance lean manufacturing and six. Lean in the opinion of the employees of production company. Systemic continuous improvementa next generation manufacturing success strategy its a manufacturers nightmare. It was put forward in 1970s by reformatting preventive maintenance pm principles which is very popular in usa in 1950s. A study conducted in 2006 by the manufacturing research center showed that only 38 percent of u. After reading you will understand the basics of this powerful quality and process management method. Total productive maintenance tpm linkedin slideshare. Total productive maintenance case study reliable plant. The function of maintenance is to find, preserve, and expand manufacturing capacity.
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