Total Productive Maintenance

TotalProductiveMaintenance- A Case StudySubmitted By,Govind.RMTM-328M.Tech(P&I)

Guide:Mr.Jenson Joseph.EAsst:ProfessorDept:Of MechanicalSSET

SEMINAR-21CONTENTS:-Definition Of TPMHistory Of TPMNeed Of TPMSteps Of TPMTPM WastesCase StudiesConclusionReference

SCMS School Of Engineering And Technology21. TPM:-Total

all employees are involved.

aims to eliminate all accidents, defects and breakdowns.

Productive

actions are performed while production goes on.

troubles for production are minimized.

Maintenance

keep in good condition.

repair, clean & lubricate.

SCMS School Of Engineering And Technology3TPM is a Lean tool for Quality and Productivity

SCMS School Of Engineering And Technology4TPM History:-Productive maintenance (PM) originated in the U.S. in late 1940s & early 1950s.

Japanese companies modified and enhanced it to fit the Japanese industrial environment.

The first use the term TPM was in 1961 by Nippondenso, a Japanese auto components manufacturer.

Seiichi Nakajima head of JIPM, one of the earliest proponents, known as the Father of TPM.SCMS School Of Engineering And Technology5Principles Of TPM:-

Increase Overall Equipment Effectiveness (OEE).Improve existing planned maintenance systems.The operator is the best condition monitor.Provide training to upgrade operations and maintenance skills.Involve everyone and utilize cross-functional teamwork

SCMS School Of Engineering And Technology67 Wastes Of TPM:-TransportationExcess productionAdded processesMotion

Waiting InventoryNon-conformance (defectives)SCMS School Of Engineering And Technology8TPM is Planned, Predictive, & Preventive:-Starts with 5s / Visual Factory.

Builds a comprehensive downtime data base by cause, frequency, and duration.

Predicts and prevents downtime by PM system .

Expands role of Operator as first point of early warning and prevention.

Professional Maintenance.

SCMS School Of Engineering And Technology9Eight Major Pillars Of TPM:-SCMS School Of Engineering And Technology10Autonomous MaintenancePlanned MaintenanceFocussed ImprovementEarly Management Of New SystemQuality MaintenanceOffice TPMEducation and trainingSafety and environmental management1. Autonomous Maintenance It means "Maintaining one's equipment by oneself.

Train the operators to close the gap between them and the maintenance staff, making it easier for both to work as a team.

2.Planned Maintenance It focusses on increasing availability of equipments & reducing breakdown of machines.

Establish Preventative & Predictive Maintenance systems for equipment and tooling.

Natural life cycle of individual machine elements must be achieved,includesCorrect operationCorrect set-upCleaningLubricationRetightening

SCMS School Of Engineering And Technology11Early Management of new equipment Establishes systems to :

new product or equipment developmentstart-up, commissioning and stabilization time for quality and efficiency

New equipment needs to be:

easy to operateeasy to cleaneasy to maintain and reliablehave quick set-up timesoperate at the lowest life cycle cost

Focussed Improvement Maximize efficiency by eliminating waste and manufacturing losses.

Manufacturing losses are categorized into 13 big losses:

Equipment lossesManpower lossesMaterial losses

SCMS School Of Engineering And Technology12Quality Maintenance Establishment of machine conditions that will not allow the occurrence of defects & control of such conditions is required to sustain Zero Defect.

6. Office TPM Administrative and support departments can be seen as process plants whose principal tasks are to collect, process, and distribute information.

SCMS School Of Engineering And Technology137. Education & Training Soft skills training: How to work as teams, diversity training and communication skills.Technical training: Upgrading problem-solving and equipment- related skills.

8. Safety Environment Create Safe & healthy work place where accidents do not occur & improve hazardous areas & do activities that preserve environment.

SCMS School Of Engineering And Technology141234567Counter measures for ContaminationPrepare Temporary StandardsGeneral InspectionAutonomous InspectionStandardizationAuto. Mgt.7 Steps Of TPM:-

7654321Initial Clean-upOIL T P MSCMS School Of Engineering And Technology1515These are the 7 steps for Operator AutonomousMaintenance:

1. Initial clean-up2. Countermeasures for Hard-to-Access & Source of Contamination3. Prepare Temporary Standards4. General Inspection5. Autonomous Inspection6. Standardization7. Autonomous ManagementBenefits Of TPM:-Equipment failures reduced.

Quality defects reduced.

Warranty claims reduced.

Maintenance costs reduce.

Productivity improved.SCMS School Of Engineering And Technology16

Case Study-1:-

Asella Malt Manufacturing Industry (Ethiopia):-

AIM:-

To evaluate the effectiveness of TPM implementation steps.

OEE value in boiler plant was calculated and analyzed before and after TPM.

Essential to maximize the production effectiveness.

SCMS School Of Engineering And Technology17the effectiveness of a plants production depends on the effectiveness withwhich it uses equipment materials people and methods17Major Losses:-Shut down (planned maintenance).

Production adjustment.

Equipment failure (mainly boiler).

Process failures.

Normal production loss.

Quality defects and reprocessing.SCMS School Of Engineering And Technology18OEE is a result can be expressed as the ratio of the actual output of the equipment to the maximum output of the equipment under the best performance condition.

18Calculations Of OEE(Before TPM Implementation):-Mechanical breakdown43.43hrElectrical breakdown11.25hrsElectronics/safety device breakdown2.03hrsTotal breakdown57.11hrsSetup and other conditions7.30hrsTotal Loss64.41hrs

Total good hours720hrsNet loss (Total good hours-Total loss)720 hrs -64.41hrs =655.19hrs

Availability rate=(Net loss Total good hours) 10090.99%Percentage of quality=(Total steamproduced-Defected steam) Total steam produced92.07%Performance rate=[Net loss-(Managementloss+Start up loss]Net loss83.97%.SCMS School Of Engineering And Technology19The bottle neck is boiler plant for malt manufacturing process due towhich productivity is going down most of the time and this plant was selectedas equipment for OEE calculation.19OEE=(Availability rate) (Performance rate) (Quality rate)100=(0.9099) (0.8397) (0.9207)=70.35%.

According to world class manufacturing performance for continuous manufacturing process industry, improvements are required urgently if OEE is less than 85% .SCMS School Of Engineering And Technology20Calculations Of OEE(After TPM Implementation):-(January)SCMS School Of Engineering And Technology21Mechanical breakdown13.35hrElectrical breakdown2.50hrsElectronics/safety device breakdown0Total breakdown16.25hrsSetup and other conditions7.30hrsTotal Loss23.55hrs

Total good hours720hrsNet loss (Total good hours-Total loss)720 hrs -23.55hrs =696.05hrs

Availability rate=(Net loss Total good hours) 10096.67%Percentage of quality=(Total steamproduced-Defected steam) Total steam produced98%Performance rate=[Net loss-(Managementloss+Start up loss]Net loss84.91%.OEE=(Availability rate) (Performance rate) (Quality rate) 100%=(0.9667) (0.8491) (0.9774)=85.23%.

SCMS School Of Engineering And Technology22Before TPMAfter TPMMonthOEE ValueMonthOEE ValueJanuary70.35%May75.60%February66.44%June80.21March70.81%July85.23Result:-Progressive growth in OEE(Reached with World Class Value)

Increase in equipment availability.

Rejection and increase in rate of performance.

Repairs reduced due to very limited products rejected due to equipment failure.SCMS School Of Engineering And Technology23Autonomous maintenance activities were carried out with totalemployee participation.23Steel Company in Jordan.

Data taken along 15 working Days.

Company produces different type of steel and used different types of plate .

Company running in 2 Shifts.

Three main workstations.1st- Oven2nd Dies(failure Occurs)3rdCooling Bed

SCMS School Of Engineering And Technology24Case Study-2:-

The data taken along fifteen working days and teams formed in period of two months to find out the benefit of formation a multidiscipline team from different department to eliminate any boundaries between the departments and make the maintenance process more effectively, labors on the production line also included in way to adopt the autonomous maintenance operations (daily maintenance) 24Datas Of Shift A(15 Days):-SCMS School Of Engineering And Technology25

Datas Of Shift B(15 Days):-

OEE is calculated as 55% which is too low.SCMS School Of Engineering And Technology26

Total Loss Calculation:-Implemented TPM:-Good quality inspection system and monitoring.

Creation of the quality improvement team.

Trained employees to identify the problems.

Use of data for a continuous improvement.

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