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      Do you want to implement the following in your organisation?

      01 Enhance employees’ capabilities

        

      02 Improve equipment reliability resulting in fewer breakdowns and less downtime

        

      03 Improve product quality, resulting in fewer defects better customer satisfactions

        

      04 Reduce maintenance costs

        

      05 Training on the TPM principles and practices

        

      TPM philosophy

      TPM emphasises proactive preventative maintenance to maximise the operational efficiency of equipment. It blurs the distinction between the roles of production and maintenance by placing a strong emphasis on empowering operators to help maintain their equipment.

      apartment

      Build a profitable operation

      Make production more economical by eliminating accidents, quality defects and breakdowns.

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      Use hands-on shop floor approach

      Bring the into its ideal state, introduce extensive visual control and create clean, uncluttered, and well-organised workplaces.

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      Involve Everyone

      Practice participatory management and treat everyone with respect and organize the workforce into a pyramid of overlapping small groups, and have operators carry out Jishu-Hozen (AM). Practice prevention rather than cure i.e. practice product and equipment, planned maintenance.

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      Create a virtuous circle of workplace expertise

      Develop a self-sustaining, continuosly-evolving culture of self directed workplace management.

      The purpose of TPM

      The overall goal of TPM is to improve overall equipment efficiency, reduce costs, and increase customer satisfaction by ensuring high-quality and reliable products are produced efficiently.

      Conventional Thinking 

      I operate - You fix, resulting into breakdown maintenance.

      TPM Thinking 

      I operate – I maintain, resulting into breakdown prevention.

      TPM

      Total

      Total efficiency

      Total life cycle of production system

      Total manpower coverage

      Productive

      Productivity maximization by

      Zero accidents

      Zero defects

       Zero injuries

      Maintenance

      Maintenance covers

      Individual processes

      Plants

      Products

      Manufacturing systems

      Improve the company

      Improve the people

      Develop people with skills required for todays highly automated factories operators: Do Jishu-Hozen  (autonomous maintenance)

      Maintenance staff: Do advanced, specialized maintenance

      Product engineers: Plan maintenance  - free equipment

      Improve the equipment

      Develop people with skills required for todays highly automated factories

      Raise OEEs by improving the equipment currently in use

      Assign new equipment for minimum life cycle cost and vertical startup

      Pillars of TPM

      The eight pillars of TPM are focused on improving equipment reliability and maintenance efficiency. These pillars include autonomous maintenance, planned maintenance, quality maintenance, focused improvement, early management, training and education, safety, and environmental management. By implementing these pillars, organisations can achieve higher productivity, better equipment performance, and increased customer satisfaction.

      • Kobetsu-kaizen (Focused improvement)
      • Jishu-Hozen (Automated maintenance)
      • Keikaku-Hozen (Planned Maintenance)
      • Training education
      • Early management (product and equipment)
      • Quality-Hozen (Quality maintenance)
      • Office TPM, TPM in admin and sup. dept.
      • SHE (Safety, Health and Environment)

      Tangible and intangible benefits of TPM

      Safety

      LIFTR, reduction in number of incidents, number of unsafe acts, number of unsafe conditions

      Environmental

      Energy saving, dust reduction in oil spillage

      Delivery

      Production compliance%, changeover time reduction

      Productivity

      OEE breakdown reduction, production rate per machine

      Quality

      In process rejections, reworks %, customer complaints

      Cost

      Consumables cost reduction 

      Typical return on Investment ( ROI) is upto 5 to 10 times

      • My machine concept and I will maintain attitude
      • Improved team work
      • Increase in ownership and accountability
      • Improved problem solving capability
      • Continuous learning and development
      • Improve in job satisfaction and motivation
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