Concept Business Excellence Pvt. Ltd. TOTAL PRODUCTIVE MAINTENANCE OVERVIEW

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1 Concept Business Excellence Pvt. Ltd. TOTAL PRODUCTIVE MAINTENANCE OVERVIEW Your partner in creating High Performing World Class Organization of CBEPL 1

2 TPM Overview What is TPM and Why TPM? TPM is a culture that focuses on improving the effectiveness of the plant, equipment and processes through the empowerment of PEOPLE. of CBEPL 2

3 Japan Institute of Plant Maintenance Aims at building up a corporate culture that thoroughly pursues production system effectiveness improvement. (Overall Equipment Effectiveness :OEE) Constructs a system to prevent every kind of loss, for example, to achieve "zero accidents, zero defects and zero failures", based on Gemba (actual site) and Genbutsu (actual thing) over the entire life cycle of a production system. Covers all departments including production, development, marketing and administration. Requires all and full involvement from top management to frontline employees. Achieves zero losses by overlapping small-group activities. of CBEPL 3

4 TPM helps to achieve Zero BAD Zero Breakdown Zero Accident Zero Defects of CBEPL 4

5 INTRODUCTION TO TPM Emergence of TPM TPM, is a Japanese Management System. During 1950 s and 1960 s Preventive Maintenance was very popular in Japan. Seichi Nakajima of JIPM, first developed and named this new approach as TPM in TPM is later improvised by JIPM as the surest means of achieving world class manufacturing. TPM is a registered trade mark of JIPM. JIPM Japanese Institute of Plant Maintenance of CBEPL 5

6 INTRODUCTION TO TPM Development of Maintenance Systems Breakdown Maintenance - Repairs Preventive Maintenance Periodic Maintenance 1950 Corrective Maintenance 1957 Predictive Maintenance CBM 1961 TPM Total Productive Maintenance of CBEPL 6

7 INTRODUCTION TO TPM TPM - The major approach to create a plant in 21st century Initially in 1970 s JIPM introduced TPM for the fabrication & assembly industries. This was developed with 5 pillars of TPM activities. Today 8 pillars have been devised. Improved employee morale Enhanced safety record Increased productivity TPM Reductio n in M/c failure Improved product quality Higher customer satisfaction Increased Profile of CBEPL 7 Cost reduction

8 8 Pillars of TPM 5S & Total Employee Involvement of CBEPL 8

9 Definition of TPM (M: Maintenance) To set a goal to maximize equipment effectiveness. (overall effectiveness). By establishing a total system for PM for the entire life of the equipment. Participation by all departments, including equipment planning, operating and maintenance departments. Involving all personnel, including top personnel to first-line operators. For promoting PM by motivation management, namely by autonomous small group activities of CBEPL 9

10 Definition of TPM (M: Maintenance) TPM MEANS Taking as a prime objective a company structure that pursues production effectiveness to its ultimate limits. (=comprehensive effectiveness) Putting together a practical shop-floor system to prevent losses before they occur throughout the entire production system's life cycle : zero accidents, zero defects, zero breakdowns Involving all function, including production, development, sales and management. Having all employees participate, from top executives to front-line workers. Achieving zero losses through overlapping small groups. of CBEPL 10

11 From TPM of Production Department to Company-wide TPM Covering All Company Activities Total Preventive Maintenance Top Management Total Productive Management Planning Financial Personnel General Affairs Production Plant Plant Plant Plant Development of Products & Equipment Sales TPM Phase 2 TPM Phase 1 TPM Phase 2 TPM Phase 1 : TPM of production Department. : Company-wide TPM encompassing production development, sales and administration. of CBEPL 11

12 Results from 250 TPM Award Winners Increase in Productivity % 50 Decrease in Breakdowns % 99 Decrease in Defect Rate % 90 Decrease in Customer Complaints % 75 Decrease in Maintenance Cost % 30 Decrease in WIP % 50 Decrease in Energy Consumption % 30 Accidents Zero Pollution Zero Increase in Employee Suggestions 10 Fold PM Prize for TPM JIPM of CBEPL 12

13 Intangible Benefits of TPM After introduction of autonomous maintenance activity, operators take care of machines by themselves without being ordered to. With achievement of Zero Breakdown and Zero Defects, operators get new confidence in their own abilities Work Places which used to be covered with oil and chips are now so clean and pleasant as to be almost un-recognisable. Improved image of the company leading to the possibility of increased orders. of CBEPL 13

14 TPM Way of Life Breakdown needs to be measured not in 3 digits but in single digit - ultimately to zero. Accidents needs to be measured by no. of dangerous working conditions not by no. of accidents occurred (near miss count). Defects needs to be measured by ppm not as a percentage. Hence TPM must be driven by top person and must come as a way of life in your company. of CBEPL 14

15 12 Steps of TPM Development Programs 1. Declaration by top management to introduce TPM Declared in TPM in house seminar, Company magazine. 2. Introductory education & campaign for TPM 3. Establishing TPM promotion organization Committees & Sub- Committees. 4. Setting basic principles and target for TPM 5. Creation of Master plan for establishing TPM 6. Kick-Off of TPM (Preparations for Introduction) of CBEPL 15

16 12 Steps of TPM Development Programs 7. Establishing systems for improving production efficiency. 7.1 Individual Improvement 7.2 Autonomous maintenance 7.3 Planned maintenance 7.4 Operation & maintenance skills upgrading training 8. Establishing initial control systems for new products and equipment. 9. Establishing Quality maintenance organization. 10. Establishing systems to improve efficiency of administration and other indirect departments of CBEPL 16

17 12 Steps of TPM Development Programs 11. Establishing Systems to control safety, Health and environments. 12. Total Application of TPM and raising its level -Application of PM award -Challenge for higher target. of CBEPL 17

18 This is a never ending journey Thank You For Your Kind Attention of CBEPL 18