Sania Sheikh (31)
Iqra Khan (32)
B.Sc. (Hons). Food Science and Technology
Semester 8th (Self Support)
INSTITUTE OF FOOD SCIENCE AND NUTRITION
UNIVERSITY OF SARGODHA, SARGODHA
CONTENTS
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Definition
Goal
Employees
Machines
Types of maintenance
Steps for implementation
OEE in TPM
8 pillars
References
DEFINITION
“System to maintain + improve
Quantity + Quality
Of
• machines
• Equipments
• Process
• Employees”
GOAL
Enhance
• Volume of production
• Employee morale
EMPLOYEE
Develop team spirit
MACHINES
Types of Maintenance
Breakdown maintenance
Preventive maintenance
Corrective maintenance
Maintenance prevention
Breakdown maintenance
Repair the equipment
when it fails
Preventive maintenance
Daily maintenance like oiling, cleaning, retightening for prevention of failure
Corrective maintenance
Improvement of equipment design and
components
Maintenance Prevention
Indicates the design of new equipment + its
comparison with old ones
STEPS FOR IMPLEMENTATION
1. Initial evaluation of TPM level of
an organization
2. Introductory education and
propaganda (IEP) for TPM
3. Form TPM committee
4. Development of master plan for
TPM
5. Stage by stage training of
employees
6. Implementation preparation
7. Establish TPM policies and goal
8. Development of a road map for
TPM implementation
OEE IN TPM
It measures how productive a process is
against the expected productivity of that
process
Availability
Performance
Quality
8 Pillars
8 PILLARS
 Autonomous maintenance
 Planned maintenance
 Quality maintenance
 Focused improvement
 Early equipment maintenance
 Education and training
 Health, safety and environment
 TPM in office functions
Pillar 1:Autonomous Maintenance
 Responsibility of basic maintenance activities
Benefits
 Operators feel responsible towards machines
 equipment becomes more reliable
 Skill levels of workers improve
 Machines operate at their optimal level
 Problems are identified and corrected
Pillar 2:Planned Maintenance
 Maintenance scheduled using the historic failure rate of
equipment
Benefits
 The number of breakdowns gradually decrease
 Production functions can continue with their activities
 Capital investments in machinery are reduced
 Maintenance is done when the production floor is not very
busy
Pillar 3:Quality Maintenance
 Quality ingrained in the equipment so as to reduce defects
 Addresses the issue of quality by ensuring equipment is able
to detect and prevent errors during production
 It helps in preventing defects from moving down the value
chain which only leads to a lot of rework
Benefits
Defect reduction
Profit
improvement
First time
right
Pillar 4: Focused Improvement
• Use of cross-functional teams for
improvement activities
Benefits
• Wide range of experienced people involved
• Improves problem solving capabilities of the
workers
Pillar 5: Early Equipment
Maintenance
• Design of new equipment using lesson learnt
from previous TPM activities
Benefits
Ease of cleaning
and inspection
Ease of lubrication
Increased safety
features
Accessibility of
equipment parts
New equipment
achieves full potential
in a short period of
time
Pillar 6: Education and Training
• Bridge the skills and knowledge gap through
training of all workers
• Through training, operators’ skills levels are
raised to the point where they are able to carryout basic maintenance activities
• The technical staff are then taught higher level
skills to help become more proactive to problem
solving
Benefits
• Employees gain the skills to solve problems
Pillar7:Health,safety and
Environment
• Providing of an ideal working environment
devoid of accidents and injuries
Benefits
Elimination of harmful conditions
Workers attitude towards work changes with
a resultant increase in productivity
Pillar 8: TPM in office functions
• Spread of the principles to administrative
functions within an organization
Benefits
• Support functions understand the benefits of
these improvements
REFERENCES
• https://en.wikipedia.org/wiki/Total_productiv
e_maintenance
• http://www.plantmaintenance.com/articles/tpm_intro.shtml