The goal of the tpm program is to markedly increase production while, at the same time, increasing employee morale and job satisfaction. The aim of this study is to focus on the most significant equipment breakdowns of the tube section of a fmcg fast moving consumer goods company and to suggest counter measures to reduce these breakdowns, which would as a result improve the oee. A flexible process improvement case study with data sets and tools for instructors to deliver multiple learning objectives. Total productive maintenance is practical technique aimed at maximizing the effectiveness of facility that we use within our organization. A project report submitted in partial fulfillment of the requirements for the award of the degree of. The companies implemented tpm because of the business difficulties they faced. Introduction t o survive in this global marketplace, companies should. Quality and maintenance of manufacturing systems are closely related functions of any organization. Implementing successful total productive maintenance tpm. Tpm improves equipment effectiveness lean production. Total productive maintenancea case study in manufacturing industry.
Design of a total productive maintenance model for effective. Elecon group of companies and ferromatik milacron india pvt. Total productive maintenance tpm implementation case study was evaluated in addressing these short comings in a confectionary manufacturing plant. Through a case study of implementing tpm in an electronics manufacturing company, the practical aspects within and beyond basic tpm theory, difficulties in the adoption of tpm and the problems encountered during the implementation are discussed and analysed. A program requires participation from all levels of an organization. The goal of the tpm program is to markedly increase production while at the same time increasing employee morale and job satisfaction. Mar 17, 2015 total productive maintenance tpm seminar and ppt with pdf report.
Total productive maintenance strategy in a semiconductor. Workplace organization and standardization 5s is a process of workplace organization and housekeeping that is carried out gradually and systematically. Sample of powerpoint in pdf format for tpm total productive maintenance course. The purpose of this paper is to evaluate the contributions of total productive maintenance tpm initiatives towards improving manufacturing performance in ethiopian malt manufacturing industry. Impacts of total productive maintenance sample essays. Total productive maintenance tpm does not have a great reputation in american industry these days. Total productive maintenance tpm is a unique approach to equipment maintenance. Root cause analysis of the major equipment breakdown problems. Index terms tpm, waste, autonomous, maintenance, multiskilling, losses i. The maintenance role of reducing downtime impacts not highly recognized. Tpm is implemented as part of the improve phase in a dmaic six sigma project. A case study article pdf available in journal of engineering and applied sciences 72.
A total or comprehensive approach to maintenance can be used to sustain. A study conducted in 2006 by the manufacturing research center showed that only 38 percent of u. Global journal of researches in engineering industrial engineering volume 12 issue 1 version 1. The main objective of this study is to determine whether the reengineering effort, based on these three tpm pillars, secsgem standard together with labour and cost, are able to minimise losses in. Systemic continuous improvementa next generation manufacturing success strategy its a manufacturers nightmare. An introduction to total productive maintenance tpm. A case study on total productive maintenance in rolling mill.
This article explains the total productive maintenance tpm in a practical way. M g r educational and research institute, chennai, tamilnadu, india s. Total productive maintenance strategy in a semiconductor manufacturer. Total productive maintenance implementation in a beverage industry. Tech production department of mechanical engineering, yeshwantrao chavan. One of the critical building blocks in the lean continuous improvement process, tpm can increase a machines. Thats where total productive maintenance tpm can help. Almost all industrial production processes are carried out with the aid of machines, as a result of which each productionoriented organization is largely dependent on. Root cause analysis of the major equipment breakdown. Tech production department of mechanical engineering, yeshwantrao chavan college of engineering, nagpur, india.
Pdf a case study of total productive maintenance implementation. Total productive maintenance tpm implementation in a machine. Tpm total productive maintenance total productive maintenance tpm is a worldwide known management system, born in 1971 in nippon denso, a toyota division in japan, which basic aims the loss elimination in plant processes by continuous training. The correlations between various tpm implementation. Goals and features of total productive maintenance tpm. Maintenance has a deep greater affect on corporate profitability than most managers are feeling to consider, much less admit. S t s y a next generation manufacturing success strategy y e. In response to the maintenance and support problems encountered in manufacturing environments, the japanese developed and introduced the concept of total productive maintenance tpm, initially in 1971. This page contains total productive maintenance tpm seminar and ppt with pdf report. Woldia university, total productive maintenance tpm, overall equipment. A study of total productive maintenance implementation. The japan institute of plant maintenance jipm tpm excellence awards are the global. This case study is based on a uk plant which was opened in 1968 to increase. Total productive maintenance, international journal of advance research, ideas and innovations in technology, apa narinder singh, onkar singh bhatia 2015.
The author also provides a wealth of practical casestudies, and action plans for solving everyday. Read total productive maintenance in a south african pulp and paper company. This case study has been conducted in one of the most important fmcg fast moving consumer goods company located in guwahati, assam. This paper described and analysed a case study of tpm implementation at a newspaper. Total productive maintenance and the basic pillars of tpm.
Through a case study of implementing tpm in an electronics manufacturing company, the practical aspects within and beyond basic tpm theory, difficulties in the. Tech production, 2assistant professor, 3student, m. Total productive maintenance tpm implementation in a. In many cases, light training will be required to bring up the skill level of operators. Total productive maintenance is a methodology used to improve the quality and the integrity of production by enhancing the various components of a company including the employees, processes and equipment. Steven borris annotation reduce or eliminate costly downtimeshort on teory and long on practice, this book provides examples and case studies, designed to provide maintenance engineers and supervisors with a. This waste is due to operators, maintenance personal, process, tooling problems and nonavailability of components in. The maintenance team were tasked with identifying all planned maintenance tasks associated with the line based on the manufacturers recommendations for the equipment. Tpm is a process that maximizes the productivity of your equipment for its entire life. After reading you will understand the basics of this powerful quality and process management method what is total productive maintenance tpm. Sharetweetsharetotal productive maintenance, also known as tpm, is a proactive equipment maintenance program that has always been a part of lean manufacturing. This is done to add value to the business organization. Jul 03, 2008 presentation on total productive maintenance 1. Pdf total productive maintenance tpm implementation in a.
This is achieved by strategically implementing the pillars of tpm on the basis of failure data, then performing a thorough root cause analysis thereof targeted improvement. Total productive maintenance establishes a system of productive maintenance, covering the entire life cycle of equipment, covers all department, involves participation of. It was developed in japan in the 1960s, but has been adapted over time to center on those who operate the equipment. Furthermore, the same analysis shows the requirement for better results of performance measurement systems is by implementing total equipment. Over a period of time two concepts have emerged which are total productive maintenance tpm and total quality management tqm along with other concepts to achieve world class manufacturing system. Tpm total productive maintenance engages operators to improve equipment. Dec 01, 2002 read total productive maintenance in a south african pulp and paper company. Each of which were assessed to determine if it could be transferred to an operator. Tpm pillar for success and also it carried out a case study in power plant industry. An introduction to tpm total productive maintenance tpm is a concept for maintaining plants and equipment. Total productive maintenance increasing efficiency management. Tpm means equipment is well maintained, eliminating any chance of failures. Address root causes that reduce the capacity of equipment.
After reading you will understand the basics of this powerful quality and process management method. Its a proactive method for predicting and preventing unplanned downtime. The role of maintenance in manufacturing has become more. Implementing successful total productive maintenance tpm in a manufacturing plant ignatio madanhire, and charles mbohwa abstract this study examines the impact of total productive maintenance tpm implementation on an organization in terms of productivity and quality levels. Citeseerx document details isaac councill, lee giles, pradeep teregowda. The paper focused on the study of total productive maintenance focused on the reasons that made the three companies implement the total. Nallusamy professor, department of mechanical engineering. Tpm, however, stands for total productive maintenance, or productive maintenance with total participation. Goal is to increase percentage of maintenance hours on planned vs. The impact of total productive maintenance practices on manufacturing performance through secsgem standard for electronic contract manufacturing companies krishnamoorthy renganathan a thesis submitted in full fulfillment of the requirements for the degree of doctor of philosophy business administration centre for graduate studies. Total productive maintenance tpm seminar ppt and pdf report. This article provides an application of the total productive maintenance tpm philosophy as a systematic means for avoiding losses and increasing productivity in an autoparts machining line.
Keep equipment operating precisely and consistently to make acceptable parts. Total productive maintenance tpm seminar and ppt with pdf report. Dale proposed paper which focuses on a study of total productive maintenance. Dale manchester school of management, umist, manchester, uk keywords total productive maintenance, implementation, organizational structure abstract this paper focuses on a study of total productive maintenance tpm in three companies. Ramakrishnan research scholar, department of mechanical engineering, dr. Implementing successful total productive maintenance tpm in.
Total productive maintenance is an innovative approach to equipment maintenance involving maintenance personnel and operators working in teams focusing on eliminating equipment breakdowns and equipment related defects. The observations and the study made are shared with the equipment manufacturer and necessary changes are made in the design of new machine. Pdf purpose the purpose of this paper is to investigate the contributions of successful total productive maintenance tpm initiatives to. Pdf total productive maintenance a case study harshi. Survey results master thesis work, innovative production, idt. First developed in japan, tpm is teambased productive maintenance and involves every level and function in the organisation, from top executives to the production floor operators. For example, in a clean and wellorganized work environment, tools and parts. This powerpoint will help you to investigate if the introduction of tpm will help you reduce lost time on operating equipment to a tune of 30% or better. Apply root cause analysis to eliminate recurring sources of quality defects. Total productive maintenance increasing efficiency. Pdf total productive maintenance implementation in a. In todays industries, the concept of total productive maintenance tpm has been widely. Time and conditionbased maintenance 299 introduction to oncondition maintenance 302 friction between maintenance and production 304 what if we were starting from scratch.
The study establishes that focused tpm implementation over a reasonable time period. S t s y a next generation manufacturing success strategy. A study of total productive maintenance implementation f. From the tools and methodology given by the lean manufacturing the study was carried out using total productive maintenance tpm and proactive approach. It started being applied in six sigma slowly but steadily, and now is widely used as six sigma control phase tool. Maintenance steven borris mcgrawhill new york chicago san francisco lisbon london madrid mexico city milan new delhi san juan seoul singapore sydney toronto. Tpm total productive maintenance the big idea getting operators involved in maintaining their own equipment, and emphasizing proactive and preventive maintenance will lay a foundation for improved production fewer breakdowns, stops, and defects. The wbdg is seeking case study examples that demonstrate the whole building design process. Impacts of total productive maintenance essay example for free newyorkessays database with more than 65000 college essays for studying. The format of the counter measure tables has been formed in partial reference to 4. A case study on total productive maintenance in rolling mill chetan s sethia1, prof. A few ways to help find root causes 315 the 5 whys 317 fishbone diagrams 320 fault tree diagrams 323. Over a period of time two concepts have emerged which are total productive maintenance tpm and total quality management tqm along with other concepts. Total productive maintenance tpm summary of tpm tpm was developed in the 1970s as a method of involving machine operators in the preventive maintenance of their machines a reaction to increasing specialization and centralization of the maintenance function that had created divisionoflabor barriers between operators and the maintenance of.
A case study of total productive maintenance implementation at precision tube mills article pdf available in journal of quality in maintenance engineering 153. International journal of advance research, ideas and innovations in technology, 14 mla. T otal p roductive m aintenance presentation by mahendra k. The case study of total productive maintenance implementation focused on its implementation, in three different companies. Routine maintenance it is a simplest form of planned maintenance, which is.
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