PI & SS-GR-1

8/14/2019 PI & SS-GR-1

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PRESENTED BY-

ABHILASH DAS (ROLL NO-01)

AJATASATRU ROUT(ROLL N0-02)SHIBA PRASAD DAS(ROLL NO-46)

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CONCEPT

“Unless the machine and equipment are in

good condition with high process

capabilities, one cannot expect defect free

production.”

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TQM

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TQM: A “Buzzword” Losing Popularity

• For many companies, the term TQM isassociated with corporate programs (mid 1980s~ early 1990s) aimed at implementing employeeteams and statistical process control.

• Unfortunately, many companies weredissatisfied with the perceived results of theseprograms, concluding TQM does not work.

Question: Why were they dissatisfied?Were they justified?

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TQM

• Total - Made up of the whole• Quality - degree of excellence a product or

service provides

• Management - Act, art or manner of planning, controlling, directing,….

Therefore, TQM is the art of managingTherefore, TQM is the art of managing

the whole to achieve excellencethe whole to achieve excellence.

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What does TQM mean? Total Quality Management means that the

organization's culture is defined by and

supports the constant attainment of

customer satisfaction through an

integrated system of tools, techniques,

and training.

This involves the continuous improvement

of organizational processes, resulting in

high quality products and services

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The three aspects of TQM

CountingTools, techniques, and training in

their use for analyzing,

understanding, and solving quality

problems

CustomersQuality for the customer as a

driving force and central concern

CultureShared values and beliefs, expressed

by leaders, that define and support

quality.

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The TQM System

Total Quality Management

CustomerFocus

ProcessImprovement

TotalInvolvement

Leadership

Education and Training Supportive structureCommunications Reward and recognitionMeasurement

ContinuousImprovement

Objective

Principles

Elements

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TPM

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Origins of TPM

• Dr. Deming introduced statistical analysis and used the

resulting data to control quality during manufacturing

(TQM)

• Some general concepts of TQM did not work well in the

maintenance environment

• The need to go further than preventive maintenance was

quickly recognized by those companies who were

committed to TQM

• Maintenance became an integral part of TQM in the

early 90’s

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Journey of Maintenance

Management(Breakdown maintenance=BM)

(Profitable preventive maintenancePPM =BM+PM)

(Productive maintenance=BM+PM+MI+PM)

(Total productive maintenance,

TPM =BM+PM+MI+PM+CI)

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Four Maintenance Models

• Corrective Maintenance

• Preventive Maintenance

• Predictive Maintenance• Total Productive Maintenance

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What is TPM ?

• To set a goal to maximize equipment efficiency (overall

efficiency).

• By establishing a total system for TPM for the entire life of

equipment.

• Participation by all departments at all levels, including

equipment planning, operating and maintenance

departments.

• Involving/motivating all personnel including top personnel to

first-line operators.

• For promoting TPM by motivation management, namely, by

autonomous small-group activities/voluntary activities.

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15

PRINCIPLESPRINCIPLES

In its broadest sense, TPM is based on three sets of

principles1. Maintenance Engineering ; Seeks to manage the

equipment life cycle, from strategic asset planning,

through design and construction, to operation,

maintenance, and disposal. Several techniques

characterize the proactive nature of maintenance

engineering including:

2. Preventive (or planned) maintenance: Planned and

scheduled maintenance activities to find and correct

problems that could lead to failure3. Predictive and condition-based maintenance:

Reducing fixed-time maintenance and relying on the

condition of equipment to determine maintenance

activity

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Eight major pillars of TPM

A u t o n o

m o u s M a i n t e n a n c e

P l a n n e

d M a i n t e n a n c e

E q u i p m

e n t a n d p r o c e s

s i m p r o v e m e n t

E a r l y m

a n a g e m e n t o f n

e w

e q u i p m e n t

P r o c e s

s q u a l i t y m a n a g

e m e n t

T P M i n

t h e o f f i c e

Education and training

Safety and environmental management

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• Total Productive Maintenance is …

operator driven reliability:

The Operators’ Creed of TPM –

Keep it clean

Keep it lubricated

Monitor for degradation

Maintain it before production is affected

Simplify and improve it

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IMPLEMENTATION

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TQM Implementation

1. Capitalize on the current village / fatherland-likeculture to facilitate the TQM process.

Ensure that the change stays and has the desired results.

Training in the basic elements of TQM must beprovided to all employees

Involved all employees in the process. Ensures that they actually take "ownership" of the processto facilitate the success of the program.

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TPM Implementation12 steps

Preparation

Kick-off

Implementation

Announcement to introduce TPMIntroductory education campaign for the workforce

TPM Promotion (special committees)

Establish basic TPM policies and goals

Preparation and Formulation of a master plan

Develop an equipment management program

Develop a planned maintenance program

Develop an autonomous maintenance programIncrease skills of production and maintenance personnel

Perfect TPM implementation and raise TPM levelsStabilization

Develop early equipment management program

Invite customers, affiliated companies and subcontractors

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7 Visual Quality Management Tools for

TPM Problem Solving

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Some research papers

• Integrating TQM and TPM into a management

information system

– International Journal of Information Technology and

Management ( Issue: Volume 1, Numbers 2-3 /

2002 Pages: 242 – 255 ) – inderscience.metapress.com

• Relationships between implementation of TQM, JIT,

and TPM and manufacturing performance

– Journal of Operations Management (Volume 19, Issue 6,November 2001, Pages 675-694 )

– www.sciencedirect.com

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CONTD….

• Relationship between TQM and TPM implementation

factors and business performance of manufacturing

industry in Indian context – Journal: International Journal of Quality & Reliability

Management

( Volume: 22, Number: 3, Year: 2005,pp: 256-277 )

– www.emeraldinsight.com

• A Comparative Review of TQM, TPM and Related

Organizational Performance Improvement Programs – This paper appears in: Emerging Trends in Engineering and

Technology, 2008. ICETET '08. First International Conference on

Publication Date: 16-18 July 2008

On page(s): 725-730

– ieeexplore.ieee.org

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Career Opportunities in TQM &

TPM• TPM officer

• Process Improvement Manager

• Quality Consultant

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CONCLUSIONTotal Productive Maintenance (TPM) Aims at

• Zero breakdown

• MTBF (mean time between failures should be minimized)

• MTRR (mean time to repair) should be brought down by breakdown

maintenance efficiency

• Preventive maintenance should be planned and implemented

• Predictive maintenance should be planned and implemented

• Warranty of maintenance concept should be implemented

Total Quality Management (TQM) Aims at

Zero Defect: A possibility

• Move from inspection to self audit

• Followed by successive audit

• Process capability upkeep and enhancement: statistical process control (SQC)

and statistical quality control (SQC)

• 5S Housekeeping

• Total Productive maintenance (TPM)

• Zidoka and Andon: Employee empowerment and autonomation• Poka-yoke

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“Quality is a Journey,

not a Destination”

PI & SS-GR-1

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