MAINTENANCE MANAGEMENT
MAINTENANCE MANAGEMENT
MODULE 5Total productive maintenance(TPM) Definition:Total
productive maintenance is a management system for optimizing the
productivity of manufacturing equipment through systematic
equipment maintenance.TPM concept means that all employees works in
small group to maximize the improvement of equipment
efficiency.Operators are working independently with all maintenance
activities of their own equipment and have also the total
responsibility of operation and maintenance.
Its a maintenance programme which involves a newly defined
concept for maintaining plants and equipments.The goal of the TPM
programme is to increase production, while at the same time
increasing employees morale and job satisfaction.Under TPM Everyone
is involved in keeping the equipment in good working order to
minimize production losses
OBJECTIVES OF TPMUse the system so as to prevent losses and to
reach zero accident, zero defect and zero breakdowns in the
manufacturing process.Obtaining zero losses by integrating the
activities of teams with the production system.Involve the entire
work force from top to bottom.
StandardsWhat is a standard?A standard is a document that
provides requirements, specifications, guidelines or
characteristics that can be used consistently to ensure that
materials, products, processes and services are fit for their
purpose
ISO 9000 CERTIFICATIONISO 9000 - Quality managementISO stands
for international organization for standardizationIt is an
international body consists of representatives from more than 90
countries.The ISO 9000 family addresses various aspects of quality
management and contains some of ISOs best known standards. The
standards provide guidance and tools for companies and
organizations who want to ensure that their products and services
consistently meet customers requirements, and that quality is
consistently improved.
ISO 9000 is a series of standards, developed and published by
the International Organization for Standardization (ISO), that
define, establish, and maintain an effective quality assurance
system for manufacturing and service industries.
IMPLEMENTATION OF ISO 9000The process of implementing ISO 9000
depends on:The sophistication(availiability) of your existing
quality program,The size of your organization, andThe complexity of
your process.(Complexity is the state of having many different
parts connected or related with each other in a complicated
way).The 14 essential steps, briefly described below, are to be
followed through in order toimplement ISO 9000 quality management
system successfully:They are as follows:Steps in implementation of
ISO 9000Step 1: Top management commitmentStep 2: Establish
implementation teamStep 3. Start ISO 9000 awareness programsStep 4:
Provide TrainingStep 5. Conduct initial status surveyStep 6: Create
a documented implementation planStep 7. Develop quality management
system documentationStep 8: Document controlStep 9.
ImplementationStep 10. Internal quality auditStep 11. Management
reviewStep 12. Pre-assessment auditStep 13. Certification and
registrationStep 14: Continual ImprovementREGISTRATION PROCESS OF
ISO 90001. Finding an ISO 9001 RegistrarYoull need to begin
searching for an ISO registrar during the 2 to 3 months your
company is still building its quality system. You can search the
Registrar Accreditation Board (RAB) at http://www.rabnet.com to
select the registrar right for you.
Selecting an ISO RegistrarSelect a registrar that has experience
within the scope category of your specific industry, which you can
also find on the RAB site. Keep in mind accreditation, scheduling
issues, fees and comfort level when selecting the registrar right
for you.
Creating an ISO Application A company and a registrar will agree
on the application contract. This is an important step of the ISO
Registration Process because it defines the rights and obligations
of both parties, and includes liability issues, confidentiality and
access rights.
4. Conducting a Quality Document Review The registrar will
require a copy of your quality manual and procedures to verify that
all the requirements of the standard are addressed. The ISO
Registration Process is not a quick process, be sure to allow 2-4
weeks in advance for the registrar to fully review all of the
necessary documents
Determining Preassessment NeedThough optional, this 2-4 week
initial review of the system identifies any significant omissions
or weaknesses. It saves time and allows the registrar to assess any
issues and resolve logistics before the actual assessment audit.The
Preassessment is an initial review of your Quality Management
System to identify any significant omissions(lack) or weaknesses in
the system and provide your organization an opportunity to correct
any deficiencies before the regular registration assessment is
conducted.
Issuing an ISO Assessment During the audit, or physical onsite
inspection of procedures in action, the auditors will issue
findings if they assess anything that doesnt meet requirements, or
nonconformities. The length of this step of the ISO Registration
Process will depend on the scope of the audit and the size your
organization.
Completing ISO 9001 Registration After all of the findings are
put into the ISO audit report and nonconformities are addressed,
your company has the option to register as ISO 9001 conformant. You
will receive a certificate and can also be listed in a register,
which the company can use to publicize its registration and use in
advertising.
8. Checking withSurveillance(careful watching of
something)Audits To ensure that the system is maintained and that
changes dont result in deficiencies in the system, registrars
perform regular surveillances of the system. Over the three-year
period of your certificate, auditors will perform one full and two
partial checks of your system
Standards in the ISO 9000 family include:
ISO 9000 SERIES has five international standards.1) ISO90002)
ISO90013) ISO90024) ISO90035) ISO9004ISO 9000This provides
guidelines for selection and use of quality management and quality
assurance standards.ISO 9001:It has 20 elements covering
design,development,production,installation and servicing.This is
applicable for the industries which are doing their own design and
development,production,installation and servicing.
ISO 9002:It has 18 elements covering production and
installation.It is same as that of ISO 9001 without the first two
tasks viz design and development.ISO9003:It has 12 elements
covering final inspection and testing for laborotories and
warehouses.etc.
ISO9004:This provides guidelines to interpret the quality
management and quality assurance.This also has suggestions which
are not mandatory.
ISO 9001:2008
ISO 9001:2008ISO 9001:2008 sets out the criteria for a quality
management system and is the only standard in the family that can
be certified to (although this is not a requirement). It can be
used by any organization, large or small, regardless of its field
of activity. In fact ISO 9001:2008 is implemented by over one
million companies and organizations in over 170 countries.
This standard is based on a number of quality management
principles including a strong customer focus, the motivation and
implication of top management, the process approach and continual
improvement.Using ISO 9001:2008 helps ensure that customers get
consistent, good quality products and services, which in turn
brings many business benefits. Certification to ISO
9001:2008Checking that the system works is a vital part of ISO
9001:2008. An organization must perform internal audits to check
how its quality management system is working. An organization may
decide to invite an independent certification body to verify that
it is in conformity to the standard, but there is no requirement
for this. Alternatively, it might invite its clients to audit the
quality system for themselves.
STATISTICAL QUALITY CONTROLQuality: Quality is a measure of how
closely a good or service conforms to specific standard.Quality
standards: may be anyone or a combination of attributes /variables
of the product being manufactured.The attributes will include
performance, reliablity, apperence, commitment to delivery time
etc.The variables may be some measurement variables like length,
width,height,diameter,surface,finish etc.
Most of the above characteristics are related to products.
Similarly some of the quality characteristics of services are
:Meeting promising due datesSafetyComfortSecurityLess wasting
time.Total quality managementTotal quality management is the
management of total quality.TQM starts with focus on customers and
it is never ending process of continuous improvement.Pillers of
TQMTOTAL QUALITY MANAGEMENTTotal quality management (TQM) consists
of organization-wide efforts to install and make a permanent
climate in which an organization continuously improves its ability
to deliver high-quality products and services to
customers.Principles of TQMBe Customer focusedWhatever we do with
the quality,finally customer is the one who determines the level of
quality.For maintaining the quality the firm need to focus on the
satisfaction and the requirement of the customers.Ensure total
employee involvementThis is done after you removes the fear from
workplace, then empower employeeto provide proper environment.
Process centeredFundamental part of TQM is to focus on process
thinking.
Integrated systemA employee must know business mission,and
vision must monitor the process.An integrated business system may
be modelled by ISO 9000Strategic and systematic approachStrategic
plan must integrate quality as core component.Continual
improvementUsing analytical and creative thinking in finding ways
to become more effective.Fact based decision makingDecision making
must be only on data,not personal thinking or
situational.CommunicationCommunication strategy, method and
timeliness must be well defined.To be successful implementing TQM,
an organization must concentrate on the eight key
elements:Ethics.Integrity.Trust.Training.Teamwork.Leadership.Recognition.Communication.
TQM MODEL
PDCA CYCLE FOR TQM
BENEFITS OF TQMStrengthened competitive positionAdaptability to
changing or emerging market conditions and to environmental and
other government regulationsHigher productivityEnhanced market
imageElimination of defects and wasteReduced costs and better cost
managementHigher profitabilityImproved customer focus and
satisfactionIncreased customer loyalty and retentionIncreased job
securityImproved employee moraleEnhanced shareholder and
stakeholder valueImproved and innovative processes
