TPM1

Prepared By:

Priyanshu Jaiswal

• Total Productive Manufacturing• Total Perfect Management• Total Profit Management• Total People Management• Total Productive Management• Total Productive Maintenance

What is TPM: 2

• TOTAL EFFECTIVENESS - Pursuit of economic efficiency, profitability.

• TOTAL PM - Maintenance prevention, improve maintainability and preventive maintenance(covering whole life cycle of production system.)

• TOTAL PARTICIPATION -Autonomous maintenance by operators and small group activity in all department, at all level.

TPM = TOTAL PRODUCTIVE MAINTENANCE

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• Zero Stoppage• Zero Defects• Zero Accidents

Objective of TPM:4

• Work• Work Place• Work Relation

TPM Creates Change in:5

• Zero Break Down • Reduce the Waste• Continual Improvement• Profit increased by cost reduction

Benefits of TPM:6

Example of Profit by Cost Reduction: 7

Cost + Profit = Price

Cost to Produce

Some Profit

Price to SellBigger Profit

8Efficient Manufacturing:Is a manufacturing philosophy which shortens the line between the customer order and the product shipment by eliminating waste.

Waste

Waste

Product Shipment

Product Shipment

Business as Usual :

Lean Manufacturing :

Customer Order

Customer Order

Waste Percentage: 9

• Overproduction• Excess Inventory• Non-value Added

Processing• Product Defects• Wait Time• Underutilized Labor• Excess Motion• Unnecessary

Transportation

10Waste Percentage:

Typically 95% of Total Lead Time is Non - Value Added!!!

TOTAL

LEAD

TIME

16 Major Losses:

1) 8 Losses Related to Equipment2) 5 Losses Related to Manpower3) 3 Losses Related to Energy & Materials

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16 Major Losses:

1) 8 Losses Related to EquipmentI. Shutdown lossII. Equipment failureIII. Setup and adjustment lossIV. Cutting blade and jig change lossV. Start up lossVI. Minor stoppage & idling lossVII. Speed lossVIII.Defect and rework loss

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16 Major Losses:

2) 5 Losses Related to ManpowerI. Management lossII. Operating motion lossIII. Line organization lossIV. Logistics lossV. Measurement & adjustment loss

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16 Major Losses:

3) 3 Losses Related to Energy & Materials;I. Energy lossII. Yield lossIII. Die, Tool & Jig loss

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TPM 8 Pillar for Reduce the Waste: 15

TPM 8 Pillars

KOBETSU

KAIZEN

QUALITY

MAINTA.

EDU

&

TRAINING

SAFETY

&

HEALTH EN.

EARLY

MANAGEMENT

OFFICE TPM

JISHU

HOZEN

PLANNED

MAINTA.

How to do the improvement by TPM: 16

Loss Identification

Loss Data Collection

Loss Data Analysis

Loss Target Setting

Loss/Cost Matrix

Pillar Targets

Circle Target

17Difference between TQM & TPM:

• TQM:- to increase the quality of goods, services and customer satisfaction by raising awareness of quality concerns across the organization.

• TPM :- It focuses on the equipment used to produce the products, by preventing equipment break-down, improving the quality and by standardizing the equipment

TPM can be seen as a way to help achieving goal of TQM

18Conclusion:

TPM Enhance Effectiveness Product Standardization Optimum Utilization of Resources Cost Reduction/ Profit Maximization

Thank You Questions?

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Thank You for your Attention & Coordination…