Total Productive Maintenance

Made by: Khaled Elsayed Hamed
Supervised by: dr.Mousa

Abstract
Total productive maintenance (TPM) is a concept applied to improve the overall equipment efficiency (OEE) and the capabilities and skills of the workers in the plant. It is founded on eight pillars to support the concept And achieve three goals. Japan institute of plan maintenance (JIPM) is the leading body of TPM.
The history of Total Productive Maintenance (TPM)

TPM has been developed from the original PM (preventive maintenance or productive maintenance) concept and methodology introduced from the USA. It has been further developed and implemented in many Japanese companies, and is now rapidly becoming a method applied worldwide.
In 1971, Nippon Denso Co., Ltd. first introduced and successfully implemented TPM in Japan. They won the Japan Institute of Plant Maintenance (JIPM) PM Excellent Plant Award for their activities. This was the beginning of TPM in Japan. Since then, TPM has spread progressively throughout the world and established itself as a renowned cultural improvement programme
The first example of TPM used in Europe to deliver world class performance was by Volvo in Ghent, Belgium, who won the PM prize for their work in the paint shop. This was quickly followed in the early 1990s by other European automotive companies trying to close the productivity and quality gap to their Japanese competitors.
Since the JIPM TPM awards were founded, over 3000 organizations have won awards, including Unilever, Wrigley, Tetra Pak, Heineken and Arcelor Mittal.
The Japan Institute of Plant Maintenance (JIPM) approach to TPM

The Japan Institute of Plant Maintenance (JIPM) TPM Excellence Awards are the global benchmark for businesses achieving this level of sustained success.

The JIPM definition of TPM is:
T = Total. must involve all employees at all levels of the organization.
P = Productive. Effective utilization of all resources.
M = Maintenance. Keeping the Man-Machine-Material system in optimum condition.

JIPM developed an eight pillar approach to TPM focused on achieving:
• Zero Accidents
• Zero Break-downs
• Zero Defects

Eight pillars are:

1. Focused Improvement 2. Autonomous Maintenance 3. Planned Maintenance 4. Training and Education 5. Early Management 6. Quality Maintenance 7. Office TPM 8. Safety, Health and Environment

1-Focused improvement pillar
What is Focused Improvement?

Focused Improvement is the first pillar of TPM. It provides a structured, team-based approach to drive elimination of specifically identified losses in any process.
How is the Pillar implemented?

The pillar follows a structured set of steps aligned to the Plan, Do, Check, Act (PDCA) cycle, which can be implemented for improvement activities of any size or complexity in any organization.
The pillar builds an understanding and analysis of the different loss types affecting an organization. The pillar operates at a strategic level, identifying the criteria for project selection and TPM deployment that will deliver the business objectives.
The pillar develops the capabilities of teams to be self-sufficient in applying appropriate problem solving approaches. By building competencies and embedding behaviors, the pillar ensures that the workforce has the skills and motivation to eliminate loss from their processes, not only for selected projects but also for normal every day issues.

What are the benefits of the Pillar?

As well as improving efficiency, reducing defects and improving safety performance due to eliminating losses, the Focused Improvement pillar ensures that the approach taken is consistent and repeatable to assure sustainability.

2-Autonomous Maintenance pillar
What is Autonomous Maintenance?

Autonomous Maintenance is the second of the eight pillars of TPM. It follows a structured approach to increase the skill levels of personnel so that they can understand, manage and improve their equipment and processes.
The goal is to change operators from being reactive to working in a more proactive way, to achieve optimal conditions that eliminate minor equipment stops as well as reducing defects and breakdowns.
How is the Pillar implemented?

The Autonomous Maintenance pillar activity is broken down into three phases and is owned by the team who use the equipment on a daily basis.
The first phase establishes and maintains basic equipment conditions through restoration and eliminating causes of forced deterioration and sources of contamination. Standards are introduced for cleaning, inspection, tightening and lubrication to ensure the conditions are sustained.
The second phase increases the capabilities of the team by training them in the detailed operating principles of the equipment and then improving the standard basic condition.
During the third phase, the operators take total ownership of the equipment as self-directed teams, continuously improving equipment condition and performance to further reduce losses.

What are the benefits of the Pillar?

The deployment of Autonomous Maintenance will improve Overall Equipment Effectiveness (OEE) by reducing performance loss and increasing equipment availability. In addition there will be measurable improvement to employee engagement and capability levels.

3-Planned maintenance pillar
What is Planned Maintenance?

Planned Maintenance is the third pillar of TPM and aims to achieve zero breakdowns. It follows a structured approach to establish a management system that extends the equipment reliability at optimum cost.

How is the Pillar implemented?

The Planned Maintenance pillar activities are normally led by the maintenance team. The initial phase prioritizes equipment and involves evaluating current maintenance performance and costs to set the focus for the pillar activity. Support is provided to the Autonomous Maintenance pillar to establish a sustainable standard basic condition and the team focuses on eliminating the causes of breakdowns.
Information management systems are used to provide detailed data on the maintenance process and the use of spares. The team identifies the optimum approach to maintaining the equipment, starting with a Periodic Maintenance (Time-Based Maintenance) system before introducing Predictive Maintenance (Condition-Based Maintenance) systems where they are appropriate and cost effective.
Finally the team drives continuous improvement of the process, eliminating reactive activities and assuring machine reliability.

What are the benefits of the Pillar?

The primary benefit from implementing Planned Maintenance is the reduction in breakdowns, which leads to reduced cost and improved machine efficiency. The pillar will also contribute to improved quality and safety performance.

4- Training and Education Pillar

What is the Training and Education Pillar?

Training and Education is the fourth pillar of TPM. It ensures that staff is trained in the skills identified as essential both for their personal development and for the successful deployment of TPM in line with the organization’s goals and objectives

How is the Pillar implemented?

Initially the knowledge and skills required for carrying out each job are defined, in terms of both complexity of knowledge needed and the number of capable people required to support the business needs. A current state analysis assesses the current levels against the established requirements and a training plan is developed to close any gaps. This plan is implemented and evaluated to ensure that the activity generates the improved capabilities targeted.
The pillar team then design implement and improve a ‘Skill Development System’ to enable on-going development of all employees. As the TPM program develops, the pillar will expand to cover broader roles and increasingly complex training needs.

What are the benefits of the Pillar?

Increased skills and performance of all personnel throughout the organization is essential for the successful implementation of TPM. Without a strong Training and Education pillar, the impact of the first three pillars will not be sustainable.
Untapped human potential creates substantial waste within an organization. Training and Education creates a corporate environment which is able to maximize the potential of all employees and respond positively to the changing business climate, technological advances and management innovation.

5- Early Management pillar

What is Early Management?

Early Management is the fifth pillar of TPM and aims to implement new products and processes with vertical ramp up and minimized development lead time. It is usually deployed after the first four pillars as it builds on the learning captured from other pillar teams, incorporating improvements into the next generation of product and equipment design.

How is the Pillar implemented?

There are two parts to the Early Management pillar: Early Equipment Management and Early Product Management. Both approaches focus on using the lessons from previous experiences to eliminate the potential for losses through the planning, development and design stages.
For Early Equipment Management, the goal is to introduce a loss and defect free process so that equipment downtime is minimal (zero breakdowns), and maintenance costs are all considered and optimized, from commissioning onwards.
Early Product Management aims to shorten development lead times, with teams working on simultaneous activities so that vertical start up can be achieved with zero quality loss (zero defects).

What are the benefits of the Pillar?

Effective Early Management implementation will deliver reduced product and process introduction lead times, improved Overall Equipment Effectiveness and the ability to deliver in volume at the right quality from production start-up. Cost savings will be delivered both during the introduction phase and throughout the equipment or product life cycle.

6- Quality Maintenance pillar

What is Quality Maintenance?

Quality Maintenance is the sixth pillar of TPM and aims to assure zero defect conditions. It does this by understanding and controlling the process interactions between manpower, material, machines and methods that could enable defects to occur. The key is to prevent defects from being produced in the first place, rather than installing rigorous inspection systems to detect the defect after it has been produced.

How is the Pillar implemented?

Quality Maintenance is launched later in the overall TPM deployment process because certain conditions must be in place for it to be successful. These conditions are delivered by full implementation of the first four pillars.
Forced deterioration must be abolished, process problems must be eliminated and any variation in materials must be under control. Operators and maintenance must have the required capability to sustain equipment conditions.
Quality Maintenance is implemented in two phases. The first phase aims to eliminate quality issues by analyzing the defects, so that optimum conditions can be defined that prevent defects occurring. Then, the current state is investigated and improvements are implemented. The second phase ensures that quality is sustained, by standardizing the parameters and methods to achieve a zero defect system.

What are the benefits of the Pillar?

Quality Maintenance reduces the cost of quality, as waste resulting from poor quality, rework, consumer complaints and the need for inspection are reduced. Defects become a failure of the organization’s systems, not the fault of the operator, and poor quality is no longer accepted as a normal occurrence. Everyone is responsible for maintaining optimal conditions and striving for zero defects.

7-Office TPM pillar
What is Office TPM?

Office TPM is the seventh pillar and concentrates on all areas that provide administrative and support functions in the organization. The pillar applies the key TPM principles in eliminating waste and losses from these departments. The pillar ensures that all processes support the optimization of manufacturing processes and that they are completed at optimal cost
How is the Pillar implemented?

The initial preparation stage for the pillar ensures that the goals and objectives for each department are aligned to the organization’s vision and mission. There are then five key activities that the Office TPM pillar undertakes within an appropriate timeframe.
The Office TPM team implements office versions of Focused Improvement, Autonomous Maintenance and the Training and Education pillars to establish sustainable, performing processes. They deploy a flexible staffing policy to allow departments to manage peak workloads, without overstaffing, and a prioritized improvement program, by loss analysis, against the goals and objectives set in the preparatory activity phase.

What are the benefits of the Pillar?

Office TPM benefits organizations by eliminating losses in the administrative systems across the whole organization and into the extended supply chain. This delivers cost reductions in the organization’s overheads as well as supporting improvement and sustainability of the manufacturing process efficiency.
The application of Office TPM also benefits the organization by developing support functions that react flexibility to changes in customer requirement and that ensure a strong brand image is maintained.

8-Safety, Health and Environment Pillar

What is the Safety, Health and Environment Pillar?

Safety, Health and Environment (SHE) is the final TPM pillar and implements a methodology to drive towards the achievement of zero accidents. It is important to note that this is not just safety related but covers zero accidents, zero overburden (physical and mental stress and strain on employees) and zero pollution.

How is the Pillar implemented?

Although the SHE pillar is the eighth pillar of TPM, it should not be thought of as the last to be deployed. The implementation of SHE strategies occurs throughout the TPM deployment process and SHE activities are never complete.
SHE pillar activities aim to reactively eliminate the root causes of incidents that have occurred, to prevent reoccurrence, and proactively reduce the risk of future potential incidents by targeting near misses and potential hazards. The pillar team target three key areas: people’s behaviors, machine conditions and the management system. All SHE pillar activities should be aligned to relevant external quality standards and certifications.

What are the benefits of the Pillar?

The immediate benefits of implementing the SHE pillar are to prevent reoccurrence of lost time accidents and reduce the number of minor accidents as well as preventing environmental system failure. This has a direct financial saving in the cost of containment, investigation and compensation as well as reputational impact.

Conclusion
The implementation of Total Productive Maintenance(TPM) will result in increased workers' awareness and capabilities, Machine capacities, reliability, less breakdowns and increase the availability of the machines that will increase the productivity in the plant.

Reference
(1) I .F (2004),Total Productive Maintenance, SMMT Industry Forum Ltd, 2680 Kings Court,