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Tuesday 4 February 2020

What is Total Productive Maintenance (TPM) ? Pillars of TPM

What is TPM?

The full sort of TPM is Total Productive Maintenance. TPM is that the process which helps us to enhance production and quality by minimising downtime of kit.
TPM emphasizes constructive and preventive maintenance 
in order to optimize system operating performance.
 TPM focuses on keeping all equipment in fitness to avoid breakdowns and delays within the manufacturing process.

Objective of TPM:

1.Increase the productivity of plant 
2. Reduce breakdown losses caused by the equipment
3. Eliminating Defects
4. Eliminate Small stops or slow running
5. Improve skill set of employees

TPM Philosophy:

 Philosophy of TPM

Essentials of TPM:

Nine Essentials of TPM

1. Self-maintained workplace
2. Elimination of the  big losses 
3. Zero breakdowns
4. Zero defects
5. Optimal life and availability of tools
6. Self-improvement
Quick processing time  
and poor machine life cost
8. Productivity in indirect departments
9. Zero accidents

Pillars of TPM:

The eight pillars of TPM are mainly focused on proactive and preventative techniques for improving equipment reliability and they are mentioned below:

1.Autonomous maintenance
2. Planned maintenance
3. Quality maintenance
4.  Focused improvement
5. Training and Education
6. Early equipment management
7. TPM in administration
8. HSE (Health,Safety and environment)

Eight Pillars of TPM

1.Autonomous maintenance

  • It help operators to hold out simple maintenance works by themselves to stoo breakdowns.
  •  It is based on CLIT method i.e. Cleaning,Lubrication,Inspection and Tightening.
  • This activity should be done before starting of daily work.
  • The main purpose of this pillar is to coach the operator so as to take care the machine by itself.

2.Planned maintenance

  • Maintenance to be prepared for periods 
    when production equipment is not scheduled
  • Schedules maintenance tasks based on measured failure rates.
  • Reduces instances of unplanned downtime.


3.Quality maintenance

  • The fundamental concept of Quality maintenance is to realize zero defect thanks to machine malfunctioning.
  • Reduces cost by catching defects early
  • To eradicate repeated causes of 
    quality deficiencies, apply root cause analysis.

4.Focused Improvement

  • Small groups of workers work proactively together to make 
    daily, incremental changes in the  running of the equipment.
  • Combines the collective talents of a corporation to make an engine for continuous improvement.

5.Training and Education

  • Employees are trained on TPM principles.
  • The main goal of coaching is to run factory with trained and skilled operator.
  • Maintenance staff are practicing 
    preventive and preventative maintenance strategies.

6. Early equipment management

  • It guides for the design and manufacturer of the machine.
  • It focus on reducing the difficulties related to operation.
  • Directs practical knowledge and understanding of manufacturing equipment gained through TPM towards improving the planning of latest equipment.

7. TPM in administration

  • Apply TPM techniques to administrative functions.
  • Through reducing duplication in administrative activities, 
    TPM spreads benefits onto the plant floor.
  • Supports efficiency by enhancing logistical processes 
    (e.g. order management, selection and scheduling).

8. HSE (Health,Safety and environment)

  • Maintain a safe and healthy working environment.
  • Eliminates potential health and safety risks, leading to a safer workplace.
  • Specifically targets the goal of an accident-free workplace.

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