TOTAL PRODUCTIVE MAINTENANCE

1
TOTAL PRODUCTIVE MAINTENANCE

• Failure prevention

2
LEARNING OUTCOMES

• to understand the concept of Total Productive
  Maintenance (TPM)
• to understand the impact of failure for a
  fashion operation

3
DEFINITION OF TPM

• Total Productive Maintenance recognises the
  importance of reliability, maintenance and
  economic efficiencyin plant design
• Accepting that sometimes failure will occur is
  not the same as ignoring it
• (Slack et al, 2007)

4
THE FIVE GOALS OF TPM

• Improve equipment effectiveness
• Achieve autonomous maintenance
• Plan maintenance
• Train all staff in relevant maintenance skills
• Achieve early equipment management

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THE GOAL OF TPM

1. To minimise waste in a fast changing economical
   environment
2. To increase production efficiency without
   reducing product quality
3. To reduce cost
4. To reduce production time
5. To ensure non defective goods to customer

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FAILURE PLANNING
7
TYPES OF FAILURE
Environmental disruption
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FAILURE DETECTION

• In-process checks
• Machine-diagnostic checks
• Point-of-departure interviews
• Accident investigation
• Product liability
• Complaint analysis
• Critical incident analysis
• Failure mode-and-effect analysis
• Fault-tree analysis

FAILURE ANALYSIS
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FAILURE MEASUREMENTS

• Failure Rate (FR)
• Reliability
• Availability

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FAILURE ANALYSIS AND RECOVERY PLANNING
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BENEFITS WITH TPM

• Improved system reliability
• Increases productivity (by 1.5 to 2 times)
• Resolves customer complaints
• Reduces manufacturing cost (by 30)
• Satisfy customer needs (by 100)
• Right quantity, time, quality
• Reduce accidents
• Follow pollution and control measures

12
TPM vs. TQM

• SIMILARITIES
• Total commitment
• Employee empowerment
• A holistic approach to improvement

DIFFERENCES
Category TQM TPM
Object Quality Output and effects Equipment Input and cause
Method Systematisation Software oriented ParticipationHardware oriented
Goal Product and process quality Elimination of losses and wastes