TOTAL PRODUCTIVE MAINTENANCE

Total Productive Maintenance



Total Productive Maintenance

Total Productive Maintenance ( TPM )

It can be considered as the medical science of machines. Total Productive Maintenance (TPM) is a maintenance program which involves a newly defined concept for maintaining plants and equipment. The goal of the TPM program is to markedly increase production while, at the same time, increasing employee morale and job satisfaction (Nakajima, 1989a).

TPM brings maintenance into focus as a necessary and vitally important part of the business. It is no longer regarded as a non-profit activity. Down time for maintenance is scheduled as a part of the manufacturing day and, in some cases, as an integral part of the manufacturing process. The goal is to hold emergency and unscheduled maintenance to a minimum.

Why TPM

TPM was introduced to achieve the following objectives. The important ones are listed below.

Avoid waste in a quickly changing economic environment.

Producing goods without reducing product quality.

Reduce cost.

Produce a low batch quantity at the earliest possible time.

Goods send to the customers must be non defective.

Involve equipment operators in the simple, day-to-day basics of equipment cleanliness and checks to enhance employee ownership in maintaining and identifying equipment problems immediately.

Types of Maintenance

Breakdown Maintenance

It means that people wait until equipment fails and repair it. Such a thing could be used when the equipment failure does not significantly affect the operation or production or generate any significant loss other than repair cost (Hartmann, 1992).

Preventive maintenance

It is a daily maintenance ( cleaning, inspection, oiling and re-tightening ), design to retain the healthy condition of equipment and prevent failure through the prevention of deterioration, periodic inspection or equipment condition diagnosis, to measure deterioration. It is further divided into periodic maintenance and predictive maintenance. Just like human life is extended by preventive medicine, the equipment service life can be prolonged by doing preventive maintenance (Hartmann, 1992).

Periodic maintenance ( Time based maintenance - TBM)

Time based maintenance consists of periodically inspecting, servicing and cleaning equipment and replacing parts to prevent sudden failure and process problems (Hartmann, 1992).

Predictive maintenance

This is a method in which the service life of important parts are predicted based on inspection or diagnosis, in order to use the parts to the limit of their service life. Compared to periodic maintenance, predictive maintenance is condition based maintenance. It manages trend values, by measuring and analyzing data about deterioration and employs a surveillance system, designed to monitor conditions through an on-line system (Hartmann, 1992).

Corrective maintenance

It improves equipment and its components so that preventive maintenance can be carried out reliably. Equipment with design weakness must be redesigned to improve reliability or improving maintainability (Hartmann, 1992).

Maintenance prevention

It indicates the design of new equipment. Weakness of current machines are sufficiently studied ( on site information leading to failure prevention, easier maintenance and prevents of defects, safety and ease of manufacturing ) and are incorporated before commissioning a new equipment (Hartmann, 1992).

TPM - History

TPM is a innovative Japanese ...