Maintenance and reliability workers are always striving for perfect. A project report submitted in partial fulfillment of the requirements for the award of the degree of. Preventive maintenance is the process of periodically performing activities. Additionally, there is a maintenance staff who holds the responsibility for major upgrades, repairs, and maintenance. Tpm total productive maintenance is a holistic approach to equipment maintenance that strives to achieve perfect production. Total preventive maintenance encyclopedia business terms. Tpm pillarseight pillars of total productive maintenance. Ongoing maintenance of a safe and healthy workplace. 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 approach uses the skills of all employees and seeks to incorporate maintenance into the everyday performance of a facility. To keep value flowing, and maximize your sales and margin contribution, you must engage everyone in establishing and maintaining equipment and process reliability. Total productive maintenance tpm six sigma study guide. A typical example of a timebased preventive maintenance trigger is a regular inspection on a critical piece of equipment that would severely impact production in the event of a breakdown.
Total productive maintenance tpm is a lean manufacturing approach developed in japan in 1971. Tpm combines three different types of maintenance, including autonomous maintenance, preventive maintenance, and early equipment maintenance. Aug 01, 2008 practical implications the literature on classification of total productive maintenance has so far been very limited. Total productive maintenance tpm is a team and shop floor based initiative focused on optimizing the effectiveness of manufacturing equipment. The origin of tpm can be traced back to 1951 when preventive maintenance was introduced in japan. It is designed to cut maintenance costs, reduce downtime, and improve and streamline.
The goal of total productive maintenance tpm is to improve overall productivity by optimizing equipment availability. Both preventive maintenance and predictive maintenance are designed to increase the reliability of assets and reduce the amount of reactivity to failures. Total preventive maintenance total productive maintenance, tpm with lean manufacturing machine downtime becomes an intolerable situation, requiring a different approach to maintenance. Elements of a total productive maintenance tpm system. 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. Preventive maintenance is done before a failure occurs and consists of maintenance types like. Applying smed to maintenance and the use of turnaround parts 211 chapter 8. Preventive maintenance periodically checks an equipment to ensure that the equipment is operating properly and to avoid unscheduled breakdown of the machine, which causes downtime in business operation.
This means that equipment is expected to have zero breakdowns, slow runs, or defects. The scope of the book is not limited to a specific topic. Total preventive maintenance total preventive maintenance tpm is the application of preventive maintenance strategies in an organized and standardized method. Konsep preventive maintenance ini sendiri merupakan konsep yang diadopsi dari amerika serikat. 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. Pdf total productive maintenance tpm implementation.
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. Total productive maintenance tpm is an allinclusive approach to equipment maintenance that strives to achieve perfect production zero defects. Secara berkesinambungan meningkatkan semua kondisi operasional dalam sebuah sistem produksi dengan cara menstimulasi daily awareness dari semua karyawan. Total productive maintenancea case study in manufacturing industry. Pdf quality and maintenance of manufacturing systems are closely related functions of any organization. Implementing successful total productive maintenance tpm in. Total productive maintenance atau tpm adalah salah satu metode proses maintenance yang dikembangkan untuk meningkatkan produktifitas di area kerja, dengan cara membuat proses tersebut lebih reliable dan lebih.
Tpm improves equipment effectiveness lean production. Preventive maintenance is the concept wherein, operators produced goods using machines and the maintenance group was dedicated with work of maintaining those machines, however with the automation of nippondenso, maintenance became a problem, as more maintenance personnel were required. Total preventive maintenance is an approach that places the responsibility for routine maintenance on the workers who operate the machinery, rather then employing separate maintenance personnel for that function. Tpm helps workers efficiently care for the equipment and machines they work with, which will reduce costs, including money and space tied up with spare parts inventory. Tpm can be of great value and its target is to improve core business processes. 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. Pengertian total productive maintenance tpm total productive maintenance atau disingkat dengan tpm adalah suatu sistem yang digunakan untuk memelihara dan meningkatkan kualitas produksi melalui perawatan perlengkapan dan peralatan kerja seperti mesin, equipment dan alatalat kerja. How to implement a total productive maintenance plan tpm. Periodic maintenance is timebased, which involves periodically inspecting, servicing, and cleaning equipment and replacing parts to prevent problems. Total preventive maintenance, or tpm, is a type of maintenance plan used in manufacturing and industrial settings. Total preventive maintenance encyclopedia business. Time based maintenance, failure finding maintenance, risk based maintenance, condition based maintenance and predictive maintenance.
The approach includes a number of methodologies still widely used today such as the six big losses, and is well suited to the smart factory and its iot use cases. An introduction to total productive maintenance faculty. Keep your equipment fully functional with total productive maintenance. Tpm depends on 5s, oee, 8 pillars, autonomous and planned maintenance. Appropriate implementation of total productive maintenance tpm offers tremendous potential in improving, not only the equipment efficiency and effectiveness, but in areas of quality, flexibility and employeework friendliness as well.
Graphic products also offers a tpm infographic, which outlines the eight management pillars, that can be copyandpasted for highresolution reprinting or posting. 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. Receive a complimentary total productive maintenance guide to reduce or even eliminate machine failure or tool downtime and boost efficiency in your workplace. Fokus utama total productive maintanance atau tpm ini adalah untuk memastikan. Tpm emphasizes proactive and preventative maintenance to maximize the operational efficiency of equipment. 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. Uses predictive and preventative maintenance to maximize equipment effectiveness. What is tpm total productive maintenance productivity.
It has been further developed and implemented in many japanese. Preventive maintenance is the concept wherein, operators produced goods using machines and the maintenance group was dedicated with work of maintaining those machines, however with the automation of nippondenso, maintenance became a problem, as. Mar 05, 2017 the need to go further than preventive maintenance was quickly recognized by those companies who were committed to tqm maintenance became an integral part of tqm in the early 90s 3. Total preventative maintenance or tpm is a set of techniques which ensures that each and every machine in the production process is always able to perform its required task. Preventive and predictive maintenance 700zb00102 42. That task can be aimed at preventing a failure, minimising the consequence of the failure or assessing the risk of the failure occurring. The maintenance department will take on the role of teachers and guides to provide training, advice and equipment information to the teams. The need to go further than preventive maintenance was quickly recognized by those companies who were committed to tqm maintenance became an integral part of. Total productive maintenance tpm is a maintenance program which involves a newly defined concept for maintaining plants and equipment. Pdf total productive maintenance tpm implementation practice. Nippondenso was the first company to introduce plant wide preventive maintenance in 1960. Tpm also values a safe working environment with a zero accident policy.
At the top level, i see maintenance being either preventive or corrective. The maintenance staff also coaches the users and operators. In general, it is a theory related to how tools, parts and machines used for manufacturing a given item are taken care of and maintained. Total preventive maintenance is an approach that places the. The goal of the tpm program is to markedly increase production while, at the same time, increasing employee morale and job satisfaction. There are 9 types of maintenance split between preventive maintenance and corrective maintenance. The common focus is changed from fixing breakdowns to preventing them. Tpm focuses on keeping all equipment in top working condition to avoid breakdowns and delays in manufacturing. Conduct training to improve operation and maintenance skills. Total productive maintenance tpm is the process of maximizing equipment effectiveness through the active involvement of all supporting departments. It blurs the distinction between the roles of production and. Create a schedule for preventive maintenance on each piece of equipment.
When equipment breaks down or performs poorly, it causes serious disruption to your business. When we do preventive maintenance we are doing a task before a failure has occurred. Develop a planned or preventive maintenance program. Nippondenso yang merupakan pemasok toyota adalah perusahaan pertama yang memperkenalkan konsep tpm pada tahun 1960 dengan slogan productivity maintenance with total employee participation. Pdf total productive maintenance tpm implementation in a. 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. Tpm total productive maintenance engages operators to improve equipment effectiveness with an emphasis on proactive and preventative maintenance. Total preventive maintenance tpm is the application of preventive maintenance strategies in an organized and standardized method. The japan institute of plant engineers jipe realized that it was a new maintenance system tailor made for japanese corporate proceedings of the world congress on engineering 2015 vol ii wce 2015, july 1 3, 2015, london, u. An effective tpm program can empower employees to take proactive measures in the upkeep of vital machinery. Implementing successful total productive maintenance. Mengenal total productive maintenance tpm sebagai metode. Total productive maintenance tpm is an equipment management program that emphasizes operator involvement and ownership of equipment performance.
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. Total preventive maintenance is an approach that places the responsibility for routine maintenance on the workers who operate the machinery, rather then employing separate maintenance personnel for that. Oee is a metric to evaluate the effectiveness of your tpm improvements. Performance speed loss ideal cycle time operating time total pieces quality quality loss good pieces total pieces oee availability x performance x quality. Total maintenance cost is the sum of material and labor cost required to repair the item, the cost of preventive maintenance to avoid repairs, plus the cost of lost production while the unit is out of service for repairs. Tpm leads to reduced downtime, fewer stops and breakdowns, and a smaller likelihood that products will suffer quality defects during the manufacturing process. Total productive maintenance, preventive maintenance, overall equipment efficiency,boiler plant, malt manufacturing industry.
Total productive maintenance overview the history of total productive maintenance tpm tpm has been developed from the original pm preventive maintenance or productive maintenance concept and methodology introduced from the usa. It also seeks to highlight appropriate enablers and success factors for eliminating barriers in successful tpm implementation. Deciding on a maintenance strategy 2 the tpm pm analysis 214 the malfunction and pm maps 215 interpreting pm maps 220 scheduled maintenance or scheduled restoration 223 scheduled replacement or scheduled discard 226 the rcm pm analysis 227 the rcm decision diagram 228. Oct 25, 2016 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. 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. An introduction to total productive maintenance tpm. Usagebased triggers fire after a certain amount of kilometres, hours, or production cycles. Total productive maintenance promote the collaboration between all departments to focus on the. Total productive maintenance training tpm training online. Use this editable professional powerpoint presentation to teach tpm and maximize equipment effectiveness.
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. What is preventative maintenancepreventive maintenance. Action plans in implementation of total productive maintenance. A preventive maintenance schedule is a scheduled maintenance or service check of an equipment. Preventive and predictive maintenance 700zb00102 44 program results will carry to the bottomline in the form of. However the concept of preventive maintenance was taken from usa. Manufacturing plants are exposed to newer and rapidly changing paradigms. Preventive maintenance is the concept wherein, operators produced goods using machines and the maintenance group was dedicated with work of maintaining those machines, however with the automation of nippondenso, maintenance became a problem as more maintenance personnel were required. 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. The japan institute of plant maintenance jipm tpm excellence awards are the global benchmark for businesses achieving this level of sustained success.
Study guide introduction to total productive maintenance april 2006 19 tpm100sg00100. Kaizen, tpm, lean, total productive management, tpmtoolset. Total productive maintenance and the basic pillars of tpm. Total productive maintenance is a key element to reducing production losses from downtime. With each maintenance type, work orders are scheduled well in advance of when maintenance is actually performed, making them both a form of scheduled maintenance.
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