Total Productive Management (TPM)

Presenter : Rokov N. Zhasa

(NU Reg. No.- 111291 of 2011-2012)
Course :
MGT 401 Total Quality Management
Course Instructor : Mr. Hriyo Kayina
Date/ Time : April 17, 2013/ 0900 hr
M M X I I I - M M I V
School of
Management Studies
Nagaland University
CONTENT
School of Management Studies, Nagaland University
1.1 TPM An Introduction
1.2 Objectives of TPM
1.3 Wastes Eliminated in TPM
1.4 Equipment Maintenance Techniques
Reference
1.5 Benefits of TPM
1.6 Performance Measures of Maintenance System
1.7 VIII Pillars of TPM
1.8 Conclusion
Important
This topic is covered under UNIT V of
MGT 401 TQM, NU MBA Old syllabus.
While discussing 8 Pillars of TPM follow
the sequence !
Its coming in exam so pay attention!

School of Management Studies, Nagaland University
1.1 TPM An Introduction
School of Management Studies, Nagaland University
TPM Optimize Productivity
All Levels of Employees
Management System
Seiichi Nakajima
Institute of Plant Management, Japan
50s
Repair after breakdown
Productive
Maintenance
70s
1.2 Objectives of TPM
School of Management Studies, Nagaland University
Why TPM was launched?
Create a Collective culture
Maximum
Efficiency
Accidents
Defects Breakdowns
Losses
0
1.3 Waste Eliminated in TPM
School of Management Studies, Nagaland University
Break Down
Setup/ Changeovers
Idling/ Minor Stopover
Reduced Eqpt. Speed
Defects & Rework
Start-up
6
Big
Losses
1.4
Equipment Maintenance Techniques
School of Management Studies, Nagaland University
Preventive Maintenance
Corrective Maintenance
Time Based Maintenance
Predictive Maintenance
Maintenance prevention
Break down Maintenance
1.5
Performance Measures of Maintenance System
School of Management Studies, Nagaland University
OEE % =uptime % x Speed % x Quality %
Uptime % =
(MTBF-MTTR)
X 100
MTBF
MTBF =
Total Running Time

No. of failures
Speed (%) Efficiency =
Actual cycle time
X 100
Design cycle time
Quality (%) Efficiency
=
Good parts produced
X 100
Total parts produced
1.6 The 8 Pillars of TPM
School of Management Studies, Nagaland University


TPM
VII Pillars
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1.6.1 5 S
School of Management Studies, Nagaland University
5 S
1. SEIRI (Sort out)
5. SHITSUKE
(Self-discipline)
2. SEITON (Organise)
3. SEISO
(Shine the work place)
4. SEIKETSU
(Standardization)
1.6.2
Jishu Hozen (Autonomous maintenance)
School of Management Studies, Nagaland University
Purpose
Prepare the operators to take care of routine maintenance tasks
Steps in JH
1. Preparation of employees
2. Initial clean-up
3. Taking counter measures for the inaccessible areas of the
machine
4. Fixing tentative JH standards
5. General inspection training for employees
6. Autonomous inspection
7. Standardization
8. Achieve OPE and OEE and other TPM targets through Kaizen
1.6.3
Kaizen
School of Management Studies, Nagaland University
Meaning
Change for better
Focus
Foundation (5 Elements)
1. Team work,
2. Personnel discipline,
3. Improved morale,
4. Quality Circles
5. Suggestions for improvement
Philosophy
Incremental Change
1. Zero losses
2. Cost reduction in all resources
3. Improvement of overall plant
effectiveness
4. Use of PM analysis
5. Easy handling of operators
6. 30% manufacturing cost
reduction
Losses
Impede equipment
efficiency
Impede human work
efficiency
Impede effective use
of production
resources.
1.6.4 Planned Maintenance
School of Management Studies, Nagaland University
Purpose
Have trouble free machines/ equipment to produce defect free products
Steps in Planned Maintenance
1. Evaluate equipment and record its present status.
2. Restore from deterioration of equipment and minimize its
weaknesses.
3. Build up information management system.
4. Prepare time based information system, select equipement
parts and memebers and map out plan.
5. Prepare predictive maintenance
6. Evaluate planned maintenance.
Types
Preventive
Maintenance
Corrective
Maintenance
Maintenance
Prevention
Breakdown
Maintenance
1.6.5 Quality maintenance
School of Management Studies, Nagaland University
Purpose
Educating operators to upgrade their skill
Focus
1. Focus on improvement of knowledge, skills and techniques.
2. Creating a training environment for self-learning based on felt
needs.
3. Training curriculum/ tools/ assessment, etc. conductive to
employee revitalization.
4. Training to remove employees fatigue and make work
enjoyable.
1.6.8 Safety, health and environment
School of Management Studies, Nagaland University
Purpose
Have zero accident, zero health damage and zero fires
How to achieve?
Creating a safe work place
Creating a surrounding area that is not damaged by
the processes and procedures.
Creating awareness among employees
Conclusion
Develop a globally competitive Industrial
Base in our State (Nagaland) and NER
School of Management Studies, Nagaland University
Our Mission
1. We must
Learn, Adopt, Adapt and Deploy TPM in our Conditions
and as per our needs
2. We must
Strive for
Excellence in the Working methods/ style needed
Excellence in the quality of our Products
Excellence in the quality of our Services
References
Panneerselvam, R. Production and
Operations Management, 2
nd
Edition, PHI
(2010)
MS 96 Total Quality Management, IGNOU

School of Management Studies, Nagaland University
End of Presentation
School of Management Studies, Nagaland University
And I am open to queries