Total Productive MaintenanceMedical Science of Machines

Prepared ByMr.P.Senthamaraikannan, M.E., (Ph.D).Assistant professor,Department of Mechanical engineering,Kamaraj college of engineering and technology,Virudhunagar.

Father Of TPM

Total Productive MaintenanceTotal• All employees • All Departments• All machines

Productive• Actions to reduce the losses

Maintenance• Keep as good as NEW

ZERO - Accident - Breakdown - Change over - Defect

To improve the useful life Period

Pillars of TPM

Autonomous Maintenance (JISHU HOZEN)

C-CleaningL-LubricationR-RetighteningI -Inspection

Steps in JISHU HOZEN

Focused Improvement (Kobetsu Kaizen)•OEE

•Transformation cost

Why losses occur?• Operation exceeds its standard timing • Non-value adding operation is performed• Machine is idle when it should have given the rated output• Machine and or man do not give the rated output• Additional time, money and energy than the specified norms

Understanding Downtime

OEE – Overall Equipment Effectiveness

OEE = Availability X Performance X Quality

Availability = 77% Performance = 95% Quality = 92%

77% x 95% x 92%

Planned Maintenance• Recoding present status• Improve weakness.• Information system• Preventive maintenance• Predictive maintenance system

Quality Maintenance• Detect the defect after it has been produced

• Prevent defects from being produced in the first place

EDUCATION AND TRAINING•A current state analysis•Develop a training plan• Implement and evaluate the plan

Safety, Health & Environment

• Safety zero accidents

• Health zero overburden (physical and mental stress and strain on employees)

• Environment zero pollution

Office TPM

• Eliminating losses in the administrative systems across the whole organization and into the extended supply chain• Cost reductions in the organization's overheads as well as supporting

improvement

Steps in introduction of TPM in a organization

Suggested Books

Suggested Website• https://www.industryforum.co.uk• https://www.jipm.or.jp/en/