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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