2 DefinitionMaintenance is defined as the management, control, execution and quality assurance of activities which ensure the achievement of optimum availability and performance of a plant in order to meet business objectives.
3 TPM - MeaningTPM is a partnership between the maintenance and production organization to improve product quality, reduce waste, reduce cost, increase equipment availability and improve maintenance state.
4 EVOLUTION OF MAINTENANCE First GenerationSecond GenerationThird GenerationFix it when it brokeHigher plant availabilityLonger equipment lifeLower CostsHigher plant reliability and availabilityGreater safetyBetter qualityCost Effectiveness1940195019601970198019902000
5 TYPES OF MAINTENANCE Corrective (or) breakdown maintenance It implies that repairs are made after failure of machine or equipmentScheduled (or) Routine maintenanceIt is a stitch-in-time procedure aimed to avoiding breakdowns
6 TYPES OF MAINTENANCE Preventive maintenance It is carried out before the failure arises (or) prior to the equipment actually breakdowns. E.g. Overhauling & Periodic upkeep.Predictive maintenanceEquipment Condition evaluated periodically and maintenance carried out.
7 OBJECTIVES OF TPM Improve Equipment Effectiveness Achieve Autonomous Plan MaintenanceTo Train all staff in maintenance skillsTo Zero Breakdowns
8 Cost Trade-off Between PM & CM 1000CostinRupe650Total cost ofmaintenanceMaintenance Activity Costs (PM)500Breakdown Penaltycosts (CM)50LOWMEDIUMMAINTENANCEHIGH
9 BIG LOSSES 1. Breakdowns Long interruptions, Costly Repairs 2. Setup and changeoverTaking Longer time than needed3.Idling time and stoppagesHard to quantify, add to big losses4.Reduced speedEquipment cycle time reduces5.Defects and reworksQuality losses & Unhappy customer
10 BENEFITS Increased productivity Equipment reliability Reduced down timeIncreased plant capacityLow production maintenance costsTeam work Between Production & Maintenance PeopleImproved safety & Profit