AnIntroductiontoTotalProductiveMaintenance(TPM)-J.Venkatesh(ven_hal@yahoo.com)Intoday’sindustrialscenariohugelosses/wastageoccurinthemanufacturingshopfloor.Thiswasteisduetooperators,maintenancepersonal,process,toolingproblemsandnon-availabilityofcomponentsintimeetc.Otherformsofwasteincludesidlemachines,idlemanpower,breakdownmachine,rejectedpartsetcareallexamplesofwaste.Thequalityrelatedwasteareofsignificantimportanceastheymatterthecompanyintermsoftime,materialandthehardearnedreputationofthecompany.Therearealsootherinvisiblewasteslikeoperatingthemachinesbelowtheratedspeed,startuploss,breakdownofthemachinesandbottlenecksinprocess.Zeroorientedconceptssuchaszerotoleranceforwaste,defects,breakdownandzeroaccidentsarebecomingapre-requisiteinthemanufacturingandassemblyindustry.Inthissituation,arevolutionaryconceptofTPMhasbeenadoptedinmanyindustriesacrosstheworldtoaddresstheabovesaidproblems.ThischapterdealsinlengthaboutthisTPM.WhatisTotalProductiveMaintenance(TPM)?Itcanbeconsideredasthemedicalscienceofmachines.TotalProductiveMaintenance(TPM)isamaintenanceprogram,whichinvolvesanewlydefinedconceptformaintainingplantsandequipment.ThegoaloftheTPMprogramistomarkedlyincreaseproductionwhile,atthesametime,increasingemployeemoraleandjobsatisfaction.TPMbringsmaintenanceintofocusasanecessaryandvitallyimportantpartofthebusiness.Itisnolongerregardedasanon-profitactivity.Downtimeformaintenanceisscheduledasapartofthemanufacturingdayand,insomecases,asanintegralpartofthemanufacturingprocess.Thegoalistoholdemergencyandunscheduledmaintenancetoaminimum.WhyTPM?TPMwasintroducedtoachievethefollowingobjectives.Theimportantonesarelistedbelow.•Avoidwastageinaquicklychangingeconomicenvironment.•Producinggoodswithoutreducingproductquality.•Reducecost.•Producealowbatchquantityattheearliestpossibletime.•Goodssendtothecustomersmustbenon-defective.SimilaritiesanddifferencesbetweenTQMandTPM:TheTPMprogramcloselyresemblesthepopularTotalQualityManagement(TQM)program.Manyofthetoolssuchasemployeeempowerment,benchmarking,documentation,etc.usedinTQMareusedtoimplementandoptimizeTPM.Followingarethesimilaritiesbetweenthetwo.1.TotalcommitmenttotheprogrambyupperlevelmanagementisrequiredinbothprogrammesJ.VenkateshMonday,April16,200712.Employeesmustbeempoweredtoinitiatecorrectiveaction,and3.Along-rangeoutlookmustbeacceptedasTPMmaytakeayearormoretoimplementandisanon-goingprocess.Changesinemployeemind-settowardtheirjobresponsibilitiesmusttakeplaceaswell.ThedifferencesbetweenTQMandTPMaresummarizedbelow.CategoryTQMTPMObjectQuality(Outputandeffects)Equipment(Inputandcause)MainsofattaininggoalSystematizethemanagement.ItissoftwareorientedEmployeesparticipationanditishardwareorientedTargetQualityforPPMEliminationoflossesandwastes.Typesofmaintenance:1.Breakdownmaintenance:Inthistypeofmaintenance,nocareistakenforthemachine,untilequipmentfails.Repairisthenundertaken.Thistypeofmaintenancecouldbeusedwhentheequipmentfailuredoesnotsignificantlyaffecttheoperationorproductionorgenerateanysignificantlossotherthanrepaircost.However,animportantaspectisthatthefailureofacomponentfromabigmachinemaybeinjurioustotheoperator.Hencebreakdownmaintenanceshouldbeavoided.2.Preventivemaintenance(1951):Itisadailymaintenance(cleaning,inspection,oilingandre-tightening),designtoretainthehealthyconditionofequipmentandpreventfailurethroughthepreventionofde...
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