Total Production Maintenance TPM

Organizational Structure for TPM Implementation
Pillars of TPM
Pillar 1 – 5S
Pillar 2 – JISHU HOZEN
Policy
- Uninterrupted operation of equipments.
- Flexible operators to operate and maintain other equipments.
- Eliminating the defects at source through active employee participation.
- Stepwise implementation of JH activities.
JISHU HOZEN Targets
- Prevent the occurrence of 1A/1B because of JH.
- Reduce oil consumption by 50%.
- Reduce process time by 50%.
- Increase use of JH by 50%.

Pillar 2 – JISHU HOZEN Contd…
Steps in JISHU HOZEN
- Preparation of employees.
- Initial cleanup of machines.
- Take counter measures.
- Fix tentative JH standards.
- General inspection.
- Autonomous inspection.
- Standardization.
- Autonomous management.
Pillar 3 - KAIZEN
Kai means change and Zen means good
The principle behind is a very large number of small improvements are move effective in an organizational environment than a few improvements of large value.

Policy
- Practice concepts of zero losses in every activity
- To achieve cost reduction targets in all resources
- To improve over all plant equipment effectiveness
- Focus of easy handling of operators

Target
- Achieve and sustain zero loses with respect to minor stops, measurement and adjustments
- It also aims to achieve 30% manufacturing cost reduction
Pillar 3 – KAIZEN Contd..
Pillar 4 – PLANNED MAINTENANACE
It is aimed to have trouble free machines and equipments producing defect free products for total customer satisfaction.

Break down into 4 categories.
- Preventive Maintenance
- Breakdown Maintenance
- Corrective Maintenance
- Maintenance Prevention

Target
- Zero equipment failure and break down.
- Improve reliability and maintainability by 50%.
Pillar 4 – PLANNED MAINTENANACE Contd..
- Reduce maintenance cost by 20%
- Ensure availability of spares all the time

Six steps in planned maintenance
- Equipment evaluation and recoding present status
- Restore deterioration and improve weakness
- Building up information management system
- Prepare time based information system
- Prepare predictive maintenance
- Evaluation of planned maintenance
Pillar 5 – QUALITY MAINTENANCE
It is aimed towards customer delight through highest quality through defect free manufacturing.

QM activity is to set equipment conditions that preclude quality defects, based on the basic concept of maintaining perfect equipment to maintain perfect quality of products.