Review Paper On: Total Productive Maintenance -IJARIIT
Narinder and Omkar, International Journal of Advance research, Ideas and Innovations in Technology.ISSN: 2454-132X(Volume1, Issue 2)Review Paper On: Total Productive Maintenance1NarinderSingh, 2Onkar Singh BhatiaStudent, Green Hills Engineering College, Kumarhatti,Solan (HP)2Associate Professor, Department of Mechanical Engineering, Green Hills Engineering College, Kumarhatti, Solan (HP)1M.TechAbstract: Importance of TPM which stands forTotal Productive maintenance for Liberalizationof global economy has resulted tough competitionin global market and for the sustainability inmarket for any product or service, theoptimization of resources and costs in all sorts isrequired. The global competition is based on theinnovation of advanced products, processes etc.and technology support is the essentialrequirement for any advancement in product orprocess where concept of Total productivemaintenance has very much relevance todaywhere it focus on improvement in equipmentavailability, performance and quality withassuring health and safety of employees andprotection of environment.TPM provides amethod for the achievement of world class levelsof overall equipment effectiveness through peopleand not through technology or systems alone. Itincludes the organizational structures, humaninteractions, analytical tools and success criteriaassociated with the implementation of TotalProductive Manufacturing programs.Keywords: Total productive ovement,PreventiveMaintenanceandreliability.health and safety of employees and protection ofenvironment. TPM helps for eliminating equipmentbreakdown and improving quality performance ofequipment, thus the achievement in TPM stronglysupports in attaining the lean concepts whichincludes the elimination of waiting time, defects inprocess etc. TPM is a program that addressesequipment maintenance through a comprehensiveproductive-maintenance delivery system coveringthe entire life of the equipment and involving allemployees from production and maintenancepersonnel to top management. It is intended to“bringbothfunctions(productionandmaintenance) together by a combination of goodworking practices, team working, and continuousimprovement.TPM is characterized by 5 key elements:1. TPM aims to maximize equipment effectiveness.2. TPM establishes a thorough system ofPreventive Maintenance (PM) for the equipment’sentire life span.3. TPM is cross-functional, implemented byvarious departments (engineering, operators,maintenance, managers).4. TPM involves every single employee.5. TPM is based on the promotion of ent and autonomous Small GroupActivity (SGA).I. INTRODUCTIONTPM focus on improvement in equipmentavailability, performance and quality with assuring 2015, IJARIIT All Rights ReservedPage 1
edMaintenanceTPMTraining andEducationQualityMaintenanceSafety, Health,EnvironmentFocusedImprovementTPM inAdministrationFigure 1.Total Productive Maintenanceimplementation of 5S random audits could beconducted using company check sheets to ensurethat it is observed in true spirits by everyone in thework place.Lack of care andproper operationAcceleratedDeteriorationFailurePoor performanceII. TPM PILLARi. Total effectiveness indicates TPM’s pursuit ofeconomic efficiency or profitability which includesproductivity, cost, quality, delivery, safety,environment, health and morale.ii. Total maintenance system includes maintenanceprevention and maintainability improvement aswell as preventive maintenance.iii. Total participation of all employees includesautonomous maintenance by operators throughsmall group activities :the small group activitiespromote planned maintenance through “motivationmanagement”.TPM starts with 5S. It is a systematic process ofhousekeeping to achieve a serene environment inthe work place involving the employees with acommitment to sincerely implement and practicehousekeeping. Problems cannot be clearly seenwhen the work place is unorganized. Cleaning andorganizing the workplace helps the team to uncoverproblems. Making problems visible is the first stepof improvement. 5S is a foundation program beforethe implementation of TPM.If this 5S is not taken up seriously, then it leads to5D delays, defects, dissatisfied customers,declining profits, and demoralized employees. This5S implementation has to be carried out in phasedmanner. First the current situation of the workplacehas to be studied by conducting a 5S audit. Thisaudit uses check sheets to evaluate the currentsituation. This check sheet consists of variousparameters to be rated say on a 5-point basis foreach ‘S’. The ratings give the current situation. Theeach of the abovementioned 5S is implemented andaudit is conducted at regular intervals to monitorthe progress and evaluate the success ofimplementation. After the completion of 2014, IJARIIT All Rights ReservedFigure 2: Root cause of failure and the impact ofownershipThe world class manufacturing concepts are: Total quality management (TQM)Total productive management (TPM)Just in time production (JIT)Total employee involvement (TEI)Continuous quality improvement (CQI)III.RELATED WORKSchmidt, S, proposed a work on Total productivemaintenance (TPM) and change over reductionengineering (CORE) are fundamental parts of thejust-in-time production system and a way toincrease productivity and quality. The major TPMimprovement activities include maximizingequipment effectiveness, eliminating the six bigequipment-related losses, autonomous maintenanceby operators and small group activities, training toimprove operation and maintenance skills and thepromotion of maintainability from the designthroughout the entire life span of the equipment.Set-up and adjustment is one of the six big losses ofTPM, and single minute exchange of dies (SMED)is the heart of just-in-time production. CORE,using newly developed software, takes SMED to anew dimension. With this approach, companieshave typically achieved over 50 per cent changeover reduction. Some companies are achievingsuccess with TPM: equipment downtimes aredrastically reduced, equipment productivity isstrongly increased and maintenance costs arereduced, process yields and product qualityPage 2
dramatically improved. This paper shows thefundamentals of TPM, its successful industrialapplication and some selected results ofmaintenance benchmarking in the manufacturingand process industry, which shows the present stateand future development of equipment andmaintenance management. The basics and someresults of CORE are presented.[1]F. Ireland and B.G. Dale proposed paper whichfocuses on a study of total productive maintenance(TPM) in three companies. The companiesimplemented TPM because of the businessdifficulties they faced. In all three companies seniormanagement had supported TPM and set upsuitable organisational structures to facilitate itsimplementation. The companies had e, although different TPM pillars hadbeen adopted, with the common ones beingimprovements, education and training, safety, andquality maintenance. The main differences in TPMimplementation related to the use of ABC machineclassification system and the role of facilitators. [2]Kathleen E. McKone a, Roger G. Schroeder b,Kristy O. Cuab In this they investigate therelationship between Total Productive Maintenance(TPM) and manufacturing performance(MP)through Structural Equation Modeling (SEM).Wefind that TPM has a positive and significantrelationship with low cost, high levels of qualityand strong delivery performance. Also find that therelationship between TPM and MP can beexplained by both direct and indirect relationships[3].Thomas R. Pomorski introduce the paper forexamines the basic concepts of TPM and reviewsthe significant literature related to design,implementation, and maintenance of TPMprogramsinmanufacturingoperations.Investigation includes the organizational structures,human interactions, analytical tools and successcriteria associated with the implementation of TotalProductive Manufacturing programs.[4]Tamer H. Haddad and Ayham A.M. Jaaron, theyproposed work where they introduce theinvestigation implementation of the TotalProductive Maintenance (TPM) program in thehealthcare industry. The study was carried out at amajor hospital in Jordan using semi-structuredinterviews coupled with documents collection andanalysis. A TPM implementation methodology hasbeen developed for increasing medical devicesutilization and decreasing their failures where thispaper is one of a few studies that investigate theapplicability of manufacturing maintenance 2014, IJARIIT All Rights Reservedsystems in other settings and that they can generatesignificant operational benefits.[5]Ahuja, I.P.S. and Khamba, J.S., The purpose of thispaper is to review the literature on Total ProductiveMaintenance(TPM) and to present an overview of TPMimplementation practices adopted by themanufacturing organizations. It also seeks tohighlight appropriate enablers and success factorsfor eliminating barriers in successful TPMimplementation.[6]Halim Mad Lazim*, T. Ramayah** andNorzieiriani Ahmad, defines the objective of TPMis to create an active participation of all employeesin maintenance and production functions, includingthe operators who operate the machines andequipments. This paper discusses part of apreliminary study finding focusing on two mainTPM practices namely autonomous maintenanceand planned maintenance in a Malaysian SME. Theresults suggest important aspects of autonomousmaintenance and planned maintenance activitiesthat contributed to the improvement in quality andcost. [7]Chompu Inwai, proposed Total productivemaintenance (TPM) is a method to improve andenhance productivity. TPM permanently improvesthe overall effectiveness of equipment, with theactive involvement of operators. This paperdescribes the pilot implementation and evaluationof TPM for the dental units in the Dental Hospital,Faculty of Dentistry, Chiang Mai University,Thailand. The paper aims to develop amethodology for increasing the dental unitutilization and availability, as well as decreasingunplanned equipment downtime. The methodologywas developed based on the first two phases of thephasedequipmentmanagementapproach;improvement of existing equipment andmaintainingimprovedequipment.Bothautonomous maintenance (AM) by operators andpreventive maintenance (PM) were implemented.Documents such as PM manual, procedures andforms were developed. Both quantitative andqualitative research methods were used to evaluatethe performance of the implemented maintenanceprogram. The experiences from this will be usefulfor other healthcare organizations that would like toimplement TPM. Furthermore, through a pilotstudy of implementing TPM in a dental hospital,the practical aspects within and beyond basic TPMtheory, difficulties in the adoption of TPM and theproblems encountered during the implementationare discussed [9]T. Ahmed and S.M. Ali1 M.M Allama2 M.S.Parvez3 introduce the critical factors which affectPage 3
the overall equipment efficiency (OEE) of thepharmaceutical industry are loading time, downtime, standard cycle time, actual cycle time, unitproduced and defect unit. Overall equipmentefficiency (OEE) is an indication of eight majorequipment related losses which are equipmentfailure, set-up and adjustment, cutting bladechange, start-up, minor stoppage and idling, speed,defect and rework and equipment shutdown. In thesecond phase of TPM implementation, a plannedmaintenance program has been suggested to makethe production process quite smooth and proficientwith increased efficiency. [10]Manu Dogra,1, Vishal S. Sharma2, AnishAchdeva2,J.S. Dureja3, proposed strategy ofmaintaining the equipment ofa plant is crucial for the effectiveness ofmanufacturing. Total productive maintenance(TPM) is a maintenance program, which involvesconcepts for maintaining plant and equipmentseffectively. In this paper detailed implementationof TPM in the cold rolling plant is discussed.Results achieved are quite encouraging in terms ofmotivated employees, improvement in overallequipment effectiveness (OEE) and reduction inno. of accidents on shop floor.[11]Melesse Workneh Wakjira, Ajit Pal Singh theyproposed significant contributions of adershipandinvolvement,traditional maintenance practices and holistic TPMimplementation initiatives, towards affectingimprovements in manufacturing performance in theEthiopian industry. The study establishes thatfocused TPM implementation over a reasonabletime period can strategically contribute mance enhancements. The study highlightsthe strong potential of TPM implementationinitiatives in affecting organizational performanceimprovements. The achievements of Ethiopianmanufacturing organizations through proactiveTPM initiatives have been evaluated and criticalTPM success factors identified for enhancing theeffectiveness of TPM implementation programs inthe Ethiopian context. [12]P.K.Suresh proposed the work for globalcompetition is based on the innovation of advancedproducts, processes etc. and technology support isthe essential requirement for any advancement inproduct or process. The advancement in technologyhad lead to the industrial revolution and higherlevel competition for survival. The implementationof these P.D.C.A approach will make resultsdefinitely and the time period for getting resultswill depends upon how fast the organization is 2014, IJARIIT All Rights Reservedadopting the changes as well as the effectiveness ofthis implementation. [13]Suzaituladwini Hashim1, Nurul Fadly Habidin2,they proposed maintenance concept is important inthe manufacturing environment and it providessupport for productivity. The purpose of this paperis to identify the TPM constructs and innovationperformance measures for Malaysian automotiveindustry and also to develop research model of theTPM and innovation performance measuresrelationship for Malaysian automotive industry. Aconceptual model based on previous studies hasbeen proposed. This model will be used to studythe relationship between TPM practices andinnovation performance for Malaysian automotiveindustry. Based on the proposed conceptual modeland reviewed, research hypotheses are beingdeveloped. The paper culminates with suggestedfuture research work [14].Kapil Sharma, Gaurav Gera, Rajender Kumar theyproposed work for the implementation of the TPMprogram in a manufacturing industry. Throughempirical study of implementing TPM in amanufacturing industry, the practical aspects withinand beyond basic TPM theory, difficulties in theadoption of TPM and problems encountered duringimplementation are discussed. By using theempirical and comprehensive approach towards themethodology results in proper implementation ofTPM. In this paper, measuring the successfulnessof TPM implementation process with direct andindirect benefits for manufacturing industries arealso discussed. [15]Tamer H. Haddad proposed TPM implementationmethodology has been developed for increasingmedical devices utilization and decreasing theirfailures. The developed employees’ workingsystem and new responsibilities were ve Maintenance (PM) and 5S Modeling,with a suggestion for additional workingperformance indicators. This paper is one of a fewstudies that investigate the applicability ofmanufacturing maintenance systems in othersettings and that they can generate significantoperational benefits. [16]Badli Shah M.Y introduces the work for surveythrough questionnaires has been applied to thisstudy to determine the level of TPM practices inautomotive industry. The Statistical Package forSocial Sciences (SPSS) software was utilized toperform the required statistical analysis of the datafrom surveys. The paper systematically categorizedthe TPM knowledge and understanding and criticalsuccess factors (CSFs) in TPM implementation.This research would provide new data and findingsPage 4
on the TPM implementation that could be used forfuture study towards improving manufacturingcompetencies through equipment maintenance inthe automotive organizations.[17]Murugadoss K Panneerselvam proposed ationinIndianmanufacturingorganizations and to formulate comprehensivestrategy for overcoming impediments to successfulTPM implementation. The analysis focuses onsystematic identification of barriers encountered byIndian manufacturing industries in their attempt toimplement TPM practices and devises mance in Indian industries through optimalstrategic TPM initiatives to confront exponentialglobal challenges. The paper divulges that TPMimplementation is by no means an easy task, whichis heavily hampered by behavioural, organisational,cultural, technological, departmental, operationaland financial obstacles. [18]Ahmad, M.F. a, Zakuan, N.b , Jusoh, A. proposedrelationship between TQM practices and businessperformance with mediators of Statistical ProcessControl (SPC), Lean Production (LP) and TotalProductive Maintenance (TPM) based on extensivereview of the literature. Study on TQM, LeanProduction, TPM and SPC generally investigate thepractices and business performance in isolation.This proposed conceptual model will help theacademicians and industry players to have betterunderstanding on the relationship between thepractices and step by step implementation toimprove business performance. The structuralequation modeling (SEM) techniques are used toexamine the relationships of the practices. [19]Miss Ashwini Mate, Suhas Bamrotwar proposedconcise exploit for implementation of totalproductive maintenance (TPM). From a practicalstudy, it is naked that challenging superiority inmaintenance practices is still a far cry. Need ofsympathetic of the technique and implementationrule emerge to be the major factors accountable forthis state therefore, it is strappingly felt that TPMjustify more attention both in practices andresearch. [20]Wasim.S.Hangad1,Dr.SanjayKumartheyproposed implementing TPM program in terms ofincreased plant efficiency and productivity areoutstanding. Depending on size, industries aremainly classified into three categories, small,medium, and large industries. Of the entirebusiness population of 3.7 million enterprises, only24,000 were medium sized (having 50 to 249employees) and fewer than 7,000 were large(having 250 or more employees). Small businesses, 2014, IJARIIT All Rights Reservedincluding those without employees, accounted forover 99% of businesses, 45% of non-governmentemployment and (excluding the finance sector)38% of turnover. In contrast, the 7,000 largestbusinesses accounted for 45% of non-governmentemployment and 49% of turnover. [21]Prof. A.Bangar1, Hemlatasahu proposed tool toimprove equipment reliability by redesign theworkforce in equipment care and improve themaintenance function. The OEE is product ofequipment availability, performance efficiency ofprocess and quality performance of manufacturingoperations. In this research we have reduced theproduction losses and improve OEE of industryupto96% by TPM based corrective action havebeen planned through this case study in a Jamnaauto industry. [22]Halim Mad Lazim, Mohamed NajibSalleh,Chandrakantan Subramaniam proposed resourceemphasized approach moves the paradigm ofmaintenance by putting emphasis on total employeeinvolvement in the maintenance activities. Westudied the relationship between TPM practices andmanufacturing performance. We investigated themoderating effect of the level of technicalcomplexity in the production process in the ps as well. [23]Ravikant V. Paropate1,
manufacturing. Total productive maintenance (TPM) is a maintenance program, which involves concepts for maintaining plant and equipments effectively. In this paper detailed implementation of TPM in the cold rolling plant is discussed. Results achieved are quite encouraging in terms of motivated employees, improvement in overall
Total productive maintenance: literature review and directions I.P.S. Ahuja and J.S. Khamba Punjabi University, Patiala, India Abstract Purpose – The purpose of this paper is to review the literature on Total Productive Maintenance (TPM) and to present an overview of TPM implementation practices adopted by the manufacturing organizations.
5 AGRICULTURAL AND PRODUCTIVE USE SOLAR COMPANIES 47 . 5.1 Relevant Government and Donor Agriculture and 48 Productive Use Programs 5.2 Agriculture and Productive Use Relevant Regulations 48 . 5.3 Productive Use Applications for Off-Grid Solar Systems 49 . 5.4 Financial Products for productive users of energy 50
1 Total Productive Maintenance (TPM) The Total Productive Maintenance is a set of methods and procedures adopted in a company as support of the production system in the logic of just-in-time and total quality control. 1.1 The evolution of the maintenance management Until the '50s, the maintenance concept was to fix items when they are broken.
in the Total Productive Maintenance (TPM) philosophy [11]. In all this, higher level of production effectiveness is attained in terms of cost effectiveness, safety, employee motivation, product quality, reduced defects rate and market positioning in order fulfillment [10]. III. TOTAL PRODUCTIVE MAINTENANCE (TPM) REVIEW
Total Productive Maintenance (TPM) and relation between 5S and Total Productive Maintenance (TPM), and conclusion is discussed in section eight. 2. Literature Review In recent years, the practice of 5S is commonly used among the Japanese firms in order to enhance human capability and productivity. Since it was introduced by
CAPE Management of Business Specimen Papers: Unit 1 Paper 01 60 Unit 1 Paper 02 68 Unit 1 Paper 03/2 74 Unit 2 Paper 01 78 Unit 2 Paper 02 86 Unit 2 Paper 03/2 90 CAPE Management of Business Mark Schemes: Unit 1 Paper 01 93 Unit 1 Paper 02 95 Unit 1 Paper 03/2 110 Unit 2 Paper 01 117 Unit 2 Paper 02 119 Unit 2 Paper 03/2 134
What is 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
What is 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
