SEMINAR-2

Total Productive Maintenance- A Case Study

Guide: Mr.Jenson Joseph.E Asst:Professor Dept:Of Mechanical SSET

Submitted By, Govind.R MTM-328 M.Tech(P&I)

CONTENTS: Definition Of TPM History Of TPM Need Of TPM Steps Of TPM TPM Wastes Case Studies Conclusion Reference
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1. TPM:Total
all employees are involved.
aims to eliminate all accidents, defects and breakdowns.

Productive
actions are performed while production goes on. troubles for production are minimized.

Maintenance
keep in good condition.
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TPM is a Lean tool for Quality and Productivity

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TPM History: Productive maintenance (PM) originated in the U.S. in late 1940s & early 1950s. Japanese companies modified and enhanced it to fit the Japanese industrial environment. The first use the term TPM was in 1961 by Nippondenso, a Japanese auto components manufacturer. Seiichi Nakajima head of JIPM, one of the earliest proponents, known as the Father of TPM.
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Principles Of TPM: Increase Overall Equipment Effectiveness (OEE). Improve existing planned maintenance systems. The operator is the best condition monitor. Provide training to upgrade operations and maintenance skills. Involve everyone and utilize cross-functional teamwork
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NEED OF TPM:Reduce defectives / scrap. Equipment breakdowns. Reduction of lost production time. Lowest possible cost by reducing waste.

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7 Wastes Of TPM: Transportation Excess production Added processes Motion

Waiting Inventory Non-conformance (defectives)

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TPM is Planned, Predictive, & Preventive:1. Starts with 5s / Visual Factory. 2. Builds a comprehensive downtime data base by cause, frequency, and duration.

3. Predicts and prevents downtime by PM system .

4. Expands role of Operator as first point of early warning and prevention. 5. Professional Maintenance.
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Eight Major Pillars Of TPM:Early Management Of New System Autonomous Maintenance Focussed Improvement Planned Maintenance Quality Maintenance

Education and training Safety and environmental management

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Office TPM

1. Autonomous Maintenance It means "Maintaining one's

equipment by oneself.

Train the operators to close the gap between them and the maintenance staff, making it easier for both to work as a team.

2. Planned Maintenance It focusses on increasing

availability of equipments & reducing breakdown of machines.

Establish Preventative & Predictive Maintenance systems for equipment and tooling.
Natural life cycle of individual machine elements must be achieved,includes

Correct operation Correct set-up Cleaning Lubrication Retightening

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3. Early Management of new equipment Establishes

systems to :
new product or equipment development start-up, commissioning and stabilization time for quality and efficiency New equipment needs to be: easy to operate easy to clean easy to maintain and reliable have quick set-up times operate at the lowest life cycle cost

4. Focussed Improvement Maximize efficiency by eliminating

waste and manufacturing losses. Manufacturing losses are categorized into 13 big losses: Equipment losses Manpower losses Material losses

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5. Quality Maintenance Establishment of machine

conditions that will not allow the occurrence of defects & control of such conditions is required to sustain Zero Defect.

6. Office TPM Administrative and support departments can

be seen as process plants whose principal tasks are to collect, process, and distribute information.

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7. Education & Training Soft skills training: How to work as teams, diversity training and communication skills. Technical training: Upgrading problem-solving and equipment- related skills.
8. Safety Environment Create Safe & healthy work place where accidents do not occur & improve hazardous areas & do activities that preserve environment.

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7 Steps Of TPM:-

T P M

Auto. Mgt. Standardization Autonomous Inspection

7 7 6 6 5 5 4 4 3 3 2 2 1 1
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OIL
General Inspection Prepare Temporary Standards

Counter measures for Contamination

Initial Clean-up
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Benefits Of TPM: Equipment failures reduced. Quality defects reduced.

Warranty claims reduced.

Maintenance costs reduce. Productivity improved.
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Case Study-1:Asella Malt Manufacturing Industry (Ethiopia): AIM: To evaluate the effectiveness of TPM implementation steps. OEE value in boiler plant was calculated and analyzed before and after TPM. Essential to maximize the production effectiveness.
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Major Losses: Shut down (planned maintenance).

Production adjustment.
Equipment failure (mainly boiler). Process failures. Normal production loss. Quality defects and reprocessing.
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Calculations Of OEE(Before TPM Implementation):Mechanical breakdown Electrical breakdown Electronics/safety device breakdown Total breakdown Setup and other conditions Total Loss Total good hours Net loss (Total good hours-Total loss) Availability rate=(Net loss Total good hours) 100 43.43hr 11.25hrs 2.03hrs 57.11hrs 7.30hrs 64.41hrs 720hrs 720 hrs -64.41hrs =655.19hrs 90.99%

Percentage of quality=(Total steam produced-Defected steam) Total steam produced

92.07%

Performance rate=[Net loss83.97%. SCMS School Of Engineering And Technology (Managementloss+Start up loss]Net loss

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 OEE=(Availability rate) (Performance rate) (Quality

rate)100=(0.9099) (0.8397) (0.9207)=70.35%.

According to world class manufacturing performance for continuous manufacturing process industry, improvements are required urgently if OEE is less than 85% .

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Calculations Of OEE(After TPM Implementation):(January)

Mechanical breakdown Electrical breakdown Electronics/safety device breakdown 13.35hr 2.50hrs 0

Total breakdown
Setup and other conditions Total Loss

16.25hrs
7.30hrs 23.55hrs

Total good hours

Net loss (Total good hours-Total loss) Availability rate=(Net loss Total good hours) 100 Percentage of quality=(Total steam produced-Defected steam) Total steam produced

720hrs
720 hrs -23.55hrs =696.05hrs 96.67% 98%

Performance rate=[Net loss84.91%. SCMSloss School Of Engineering And (Managementloss+Start up loss]Net

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 OEE=(Availability rate) (Performance rate) (Quality rate)

100%=(0.9667) (0.8491) (0.9774)=85.23%.

Before TPM Month January February March
OEE Value

After TPM Month May June July

OEE Value

70.35% 66.44% 70.81%

75.60% 80.21 85.23

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Result: Progressive growth in OEE(Reached with World Class Value)

Increase in equipment availability.

Rejection and increase in rate of performance. Repairs reduced due to very limited products rejected due to equipment failure.

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Case Study-2: Steel Company in Jordan.

Data taken along 15 working Days.

Company produces different type of steel and used different types of plate . Company running in 2 Shifts. Three main workstations.
1st- Oven 2nd Dies(failure Occurs) 3rdCooling Bed
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Datas Of Shift A(15 Days):-

Datas Of Shift B(15 Days):-

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Total Loss Calculation:-

OEE is calculated as 55% which is too low.

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Implemented TPM: Good quality inspection system and monitoring.

Creation of the quality improvement team.

Trained employees to identify the problems.

Use of data for a continuous improvement.

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