Total Productive Maintenance Management

Table of Contents:-

  • Meaning of Total Productive Maintenance Management
  • Define Total Productive Maintenance Management
  • Objectives of Total Productive Maintenance Management
  • Steps/Procedure for Implementation of Total Productive Maintenance Management
  • Advantages of Total Productive Maintenance Management
  • Maintenance Management

Meaning of Total Productive Maintenance Management

Total Productive Maintenance (TPM) management is an innovative approach to maintenance that Japanese manufacturers developed to optimize the performance of their plants and machinery. The ultimate objective of TPM is to establish an operational system that requires minimal maintenance intervention. In other words, maintenance prevention (MP) is achieved through a combination of preventive maintenance (PM) and predictive maintenance action (PMA). Through this approach,  maintainability improvement (MI) is achieved.

A full definition of TPM contains the following five points:

1) It establishes a total companywide Project Management (PM) system that incorporates preventive maintenance, maintenance prevention, and improvement-related maintenance.

2) It aims to get the most efficient use of equipment, thereby enhancing overall efficiency.

3) It involves every employee from top management to down.

4) It implements and promotes PM through the utilization of autonomous, small-group activities. 

5) It requires the participation of equipment operators, equipment designers, and maintenance department workers.

Uniting the entire company under the banner of Total Productive Maintenance (TPM) enables it to achieve goals such as zero breakdowns and zero defects, which pay off in higher productivity and enhanced profitability.

Define Total Productive Maintenance Management

In the traditional approach, breakdown maintenance replaces the defective components when a machine fails. In Total Productive Maintenance (TPM), rather than waiting for equipment breakdowns, a small group carries out preventive maintenance on a selective basis. This process is also called condition-based maintenance. The predictive maintenance concept predicts the conditions of components chosen for preventative maintenance. This process leads to maintenance-free service (MFS) or maintenance prevention (MP).

All techniques are used for predicting components or parts which are likely to breakdown. For this purpose, proper machine trouble records are maintained and MTBF is analyzed for all components/subsystems statistically, so that breakdown maintenance is carried out by a dedicated small group much before the actual breakdown of machines in the conventional sense. This small group activity is called Productive Maintenance (PRM). This group forms part of the production wing. TPM can be represented diagrammatically as follow:

Objectives of Total Productive Maintenance Management

TPM was introduced to achieve the following objectives. The important ones are listed below:

1) Avoid wastage in a quickly changing economic environment.

2) Producing goods without reducing product quality.

3) Reduce cost.

4) Produce a low batch quantity at the earliest possible time

5) Goods sent to customers must be free from defects.

Steps/Procedure for Implementation of Total Productive Maintenance Management

The procedures for TPM implementation in an organisation are as follows:

Step A: Preparatory Stage

i) Announcement by Management to all about TPM Introduction in the Organization: Proper understanding, commitment, and active involvement of the top Management are needed for this step. Senior Management should have awareness programs and a comprehensive announcement to all employees. Publish it in house magazine and display it on the notice board. If necessary, send a letter to all relevant individuals.

ii) Initial Education and Propaganda for TPM: Training will be done based on the need. Some need intensive training, while others must be aware of certain concepts. Take people who matter to places where TPM is already successfully implemented.

iii) Setting up TPM and Departmental Committees: TPM includes improvement, autonomous maintenance, quality maintenance, etc., as part of it. When committees are established, they should address all pertinent needs.

iv) Establishing the TPM Working System and Target: Each area is benchmarked and fixed up a target for achievement.

v) Master Plan for Institutionalizing: The next step is implementation, leading to institutionalising, wherein TPM becomes an organisational culture. Achieving the PM award is concrete evidence of successfully attaining a commendable level of performance.

Step B: Introduction Stage

This is a ceremony, and one should invite everyone. Suppliers should be aware that customers expect a high-quality supply from them. While some suppliers may learn from expertise, some can help so that customers will get the communication demonstrating a commitment to delivering top-notch output.

Step C: Implementation

In this stage, eight activities, called eight pillars, are carried out to develop TPM activity. Of these, four actions are for establishing the system for production efficiency, one for the initial control system of new product and equipment, one for improving the efficiency of administration, and one for controlling safety and sanitation as a working environment.

Step D: Institutionalising Stage

By doing all these activities, one would have reached the maturity stage. Now is the time to apply for the PM award. Also, think of the challenging level to which one can take this movement.

Advantages of Total Productive Maintenance Management

The benefits/advantages of TPM are as follows:

1) Increase OPE (Overall Plant Efficiency) and productivity.

2) Rectify customer complaints.

3) Reduce the manufacturing cost.

4) Satisfy the customer’s need by 100% (Delivering the correct quantity at the right time, in the required quality).

5) Reduce accidents.

6) Follow pollution control measures.

7) Higher confidence level among the employees.

8) Keep the workplace clean, neat and attractive.

9) Favourable change in the attitude of the operators.

10) Achieve goals by working as a team.

11) Share knowledge and experience.

12) Horizontal deployment of a new concept in all areas of the organization.

13) The workers get a feeling of owning the machine.

Maintenance Management

Maintenance is any action that restores failed units to an operational condition or retains non-failed units in an active state or an activity carried out for any equipment or asset to ensure its reliability in performing its functions.

The maintenance function plays a supporting role in effective operations by ensuring that the equipment is capable of maintaining quality standards, as well as meeting the quantitative and cost criteria for outputs.

Maintenance efficiency is considered an integral part of business effectiveness, influencing risk safety, environmental integrity, energy efficiency, product quality, and the customer service profile of the organization. Beyond its traditional roles of enhancing plant availability and lowering costs, maintenance ensures that all production facilities are consistently in serviceable conditions, preventing production hold-ups, interruptions, or a loss of their standard efficiency of operations.

By and large, maintenance is a neglected area in India. Preventive maintenance is conspicuously absent in most Indian industries, except the defence service. Maintenance management involves planning, organising, and controlling maintenance activities to minimize costs.

It strives to maintain optimum equipment conditions to prevent unexpected breakdowns, speed losses, and quality defects arising from process activities.

Maintenance management must address the following questions:

  1. What is to be maintained?
  2. How is the maintenance to be done?
  3. Where is the maintenance?
  4. Who performs the maintenance?

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