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WHAT IS TPM?

Medical science of machines.Newly defined concepts of maintaining plants and equipments.

Brings maintenance into focus as a necessary and vitally important part of business.

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WHY TPMTPM was introduced to achieve the following objectives.

Zero defect, Zero breakdown, Zero accident and Zero losses.

Improving Overall Equipment Efficiency (OEE) for safe and efficient operation of the

plant.

Creating a clean and pleasant work environment leading to higher employee morale and

greater operational profitability.

TPM HISTORY Total Productive Maintenance has been introduced in Japan since 1951.

Nippodenso was the first to introduce plant wide preventive maintenance in 1960.

Based on the developments Nippodenso was awarded the distinguished plant prize for

developing and implementing TPM, by the Japanese Institute of Plant Engineers(JIPE).

Thus Nippodenso of the Toyota Group became the first to obtain TPM certification.

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TYPES OF MAINTENANCE

1. Breakdown maintenance : Maintenance or rather repair work is carried out only after anequipment or machine has broken down.

2. Preventive maintenance : Timely maintenance of equipments or machines; two types:

Periodic maintenance : Regular or periodic maintenance of equipments or machines usually

during a shutdown period.

Predictive maintenance : Online monitoring of equipments or machines and prediction of a

suitable maintenance schedule without affecting production.3. Corrective maintenance : A maintenance task performed to identify, isolate and rectify a

fault so that the failed equipment , machine or system can be restored to an operational

condition within the tolerances or limits established for in-service operations.

4. Maintenance prevention : Machine engineering, designing or installation activities that is

based on preventing the need for maintenance or for ease of maintenance.

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THE 8 PILLARS OF TPM

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THE 8 PILLARS OF TPM contd..

1. Focussed Improvement(Kobetsu Kaizen): Continuously and even small steps ofimprovement and basically involves all people in the organisation.

2. Autonomous maintenance(Jishu Hozen): Means maintaining ones equpment by oneself

(for e.g. by the operator himself).

3. Planned maintenance: Focusses on increasing availability of trouble-free machines and

thereby producing quality products to ensure total customer satisfaction.

4. Quality maintenance: This is the establishment of machine condition that will not allowthe occurrence of defect and control of such is required to sustain zero defect.

5. Development management (IFC): An early management procedure to critically review an

equipment or process at the design stage itself with the objective of minimizing future

maintenance cost and deterioration loss.

6. Office TPM: To make an efficient working office that eliminates losses.

7. Educational and training: Formation of autonomous workers who have the skill andtechnique for autonomous maintenance.

8. Safety, Health and Environment: To create a safe and healthy workplace where accidents

do not occur, no risk to health and the environment as a whole.

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Education & Training

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OBJECTIVES The primary objective of E&T programme is to develop a multi-skilled, revitalized workforce

whose morale is high and has eagerness to come to work and perform all required functions

effectively and independently.

Enhance the know how as well as the know why and hence the overall development of

the workforce.

INTRODUCTION One of the eight pillars of Total Productive Maintenance (TPM)

This programme needs to be started after the commitment by the top management to

implement TPM.

This programme in addition to technical knowledge incorporates the physiological and

psychological aspects of the person concerned as well as the surrounding environment.

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4 PHASES OF SKILL.

Phase 1: Do not know.

Phase 2: Know the theory but cannot do.

Phase 3: Can do but cannot teach

Phase 4: Can do and also teach.

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STEPS IN EDUCATION AND TRAINING

Step 1 : Checking present status of education and training & setting policies and priorities

Checking whether the existing method of imparting education for traditional maintenance

technique is efficient enough.

Set up policies like improvement of knowledge, skills and techniques.

Creating a training environment for self learning based on felt needs.

Training to remove employee fatigue and make work enjoyable.

Step 2 : Establishment of training system for operation and maintenance and skill up

gradation

Organising seminars and lectures to create awareness about TPM and its advantages.

Organising sessions on role of pillar Chairman and HODs by TPM consultant.

Creating an awareness about 5S (seiri:sort out, seiton:organising, seiso:cleaning,

seiketsu:standardardisation, shitsuke:self-discipline); which is the foundation for TPM

implementation.

Organising training sessions on all the pillars either by consultants or by experts in these

fields if available in the same organisation.

Preparing One Point Lessons and setting up display at the concerned locations.

Preparing training manuals.

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STEPS IN EDUCATION AND TRAINING contd

Step 3 : Preparation of training calendar

Preparing a schedule for the various education and training programmes under TPM.

Step 4 : Kick-off of the system for training

Carrying out the training programmes as per schedule.

Step 5 : Evaluation of activities and study of future approach

At the end of a calendar period, carry out a review of the activities under TPM, by means ofsome tools like skill mapping sheet, management control report etc.

Based on the results, prepare future plans for TPM implementation for the next calendar

period.

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A proper and effective E&T programme will ultimately act as a navigator for the other

TPM pillars, and will result in the growth of an organisation in the long run.

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TRAINING METHODS - TWO BROAD TYPES

ON THE JOB

Training is provided while they are

conducting their regular works at the same

places.

Includes orientations, job instruction,

apprenticeships, internships,

assistantships, job rotation and coaching.

Time saving as learning and working goes

hand in hand.

OFF THE JOB

Basically class-room oriented.

Includes lectures, special study, audio

visual conferences or discussions, case

studies, role playing, simulation,

programmed instructions, and laboratory

trainings.

Quite an expensive means of providing

training.

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E&T TOOLS

One Point Lesson

Skill Proficiency Level Sheet

Management Control Report

Monthly Assessment Sheet

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COMPETENCY / SKILL PROFICIENCY LEVELS

0. NIL

I) Does not know anything Or

ii) No Knowledge , No Awareness.

1. BASIC (30% & below)

i) Knows Theory but Cannot Perform (no practical) or - Can Perform (Knows Practical) but No Theory Knowledge.

Or

ii) Understands and utilizes terminology and standard practices. Has sufficient knowledge to handle standard

tasks. Seeks guidance as appropriate.

2. INTERMEDIATE (60% - 31%)

i) Knows Theory & Can Perform to some extent (Needs Supervision). Or

ii) Applies theories, concepts, principles and techniques to handle a broad range of tasks and situations with

limited guidance. Exercises own judgement within the parameters of defined policies and practices.

3. ADVANCED (80% - 61%)

i) Knows Theory & Can Perform with Confidence (Needs No Supervision). Or

ii) Demonstrates in-depth knowledge through the ability to resolve complex issues. Demonstrates knowledge of

disciplines beyond own area of speciality, and keeps up-to-date with leading edge developments. Executes workindependently and provides guidance

4. EXPERT (100% - 81%)

i) Knows Theory, Can Perform with Confidence and Can Teach Others. Or

ii) Demonstrates expert ability by solving complex problems that impact the strategic direction of the organization.

Is seen as an expert or role model in this area, and imparts knowledge to others.

L0

L1

L2

L3

L4

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MANAGEMENT CONTROL REPORT

TPM Pillar Progress Assessment : LDP

Month: May Department LDPOverall

Rating*92.50 A

Pillar Member: U C MishraDepartment

HeadBrij Badhadra

Is JH Training applicable (Y/N) YPerformance Trend

Education And Training : D. S. Rekhi

Sl. No. Good KPI Unit Category Weightage Target ActualScores#

(%)Scores(Marks)

1 HNos. of Trainings (Deptt. Classroom) during the month

Nos. A 10 4.00 4 100% 10.0

2 HNos. of Employees covered (Deptt.Classroom ) during the month

Nos. A 10 10 10 100% 10.0

3 HNos. of Trainings (JH) during themonth

Nos. A 10 4 2 50% 5.0

4 HNos. of Employees covered (JH)during the month

Nos. A 10 8 8 100% 10.0

5 H Training Manhours.Man hrs. /

Emp. / Mth.

A 20 4.60 4.60 100% 20.0

6 HNos. of On-The-Job Training duringthe month

Nos. B 10 5 5 100% 10.0

7 HNos. of Employees covered (On thejob ) during the month

Nos. B 10 5 5 100% 10.0

8 HNos. of OPL's developed during themonth

Nos. B 15 5 5 100% 15.0

9 H Pillar Meeting during the month Nos. A 5 2 1 50% 2.5

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Monthly Assessment Sheet

Department : BF-I & BF-II

Month

No. of Trainings No. of Participants

Classroom On the job Classroom On the job

Annual target 18 7 288 78

April 2012

Monthly target 2 1 24 7

Achieved 4 1 21 9

Gap 2 0 -3 3

Cumulative

Target 2 1 24 7

Cumulative

Achieved4 1 21 9

Cumulative Gap 2 0 -3 2