1. Total Productive Maintenance and FTM From Werardt
A presentation by Werardt Systemss P Ltd

2. Why TPM? Increases Productivity Labor productivity, and
Break down reduction
Improves Quality by
Reducing the Defects in processes
Reducing Defects in products
Reducing Customer complaints

3. Why TPM? Reduces Cost Reduction in man power
Maintenance cost reduction
Energy Conservation
Delivery
Stock reduction
Inventory turnover increase
Safety Environment
Improvement Ideas increase
Small Group meetings increase

4. Why TPM? Financial Return on Investment (ROI) after 2 to 3 years
Break even on initial TPM project – Less than one year
Reduction in absenteeism, as work place is enriched

5. TPM Goals
Zero unplanned Downtime
Zero Defects
Zero failure
Zero variability
Reduced Idle time on machines
Zero Accidents
Maximized P.M. Compliance
Thus Maximizing OEE
FTM puts you on the road to achieve these Goals in a Simple, Better and Faster way !

6. The Pillars of TPM
1 Kobetsu Kaizen - Individual Improvements
2 Jishu-Hozen - Autonomous Maintenance
3 Planned Maintenance
4 Quality Maintenance
5 Education and Training
6 Safety and Environment
7 Office TPM
8 Development Management
TPM is a cultural change and FTM supplements it in Information management

7. Some “Facts” about TPM & Maintenance
Maintenance can generally account for a major portion of today’s manufacturing costs
Hence when it comes to TPM implementation the Maintenance department generally takes the lead
Generally upto 25% of maintenance cost is wasted or not known
Emergency repair jobs are at least three times more expensive than the same repair done a pre-planned basis.
Hence TPM & Maintenance go hand-in-hand

8. How to achieve Zero Breakdowns?
RCFA - Root Cause Failure Analysis
Making P.M. effective and dynamic
Condition & Time Based Maintenance
Doing Why-Why Analysis and maintaining 6W2H
Improving the Reliability of work
Reducing Idle time on repairs
Condition Monitoring and Inspection
Autonomous Maintenance activities
FTM is very strong in this area !

9. The FTM Steps to Success
Awareness : Understanding your activities, Identifying Critical, Essential and Desirable requirements
Business Process Optimization : What processes do you follow to achieve your objectives? Who is doing what? Are they trained for the Job? Are required skills available?
Quantification : How many and which type of Jobs do you do? To focus on the type of work being done, how much is reactive and how much is proactive?
Benchmarking : FTM helps in devising and defining your Key measuring parameters or KPI’s that help in Improvements
Performance Review : And most importantly devising a post implementation review mechanism to monitor progress

10. Maintenance Prevention Design
Facilitating autonomous maintenance or Jishu Hozen, through Activity based PM, and feedback on machine behavior
Applying Kaizen activities to monitor Improvements
Increasing the ease of operation, make it easy from information and work point of view
Improving skills through need based training programs and easy availability of history
Improving maintainability through condition monitoring and reliable operations
Improving safety through awareness
Applying FTM feedback !

11. Key Result Areas 1. Improving human resources
Operators’ ability to perform Jishu-Hozen
Maintenance employees’ ability to perform quality & reliable maintenance
Production engineers’ ability to execute maintenance free equipment plan
2. Improving Plant & Machinery
Maximizing Uptime
Increased Plant value
Achieving TPR - Total Plant Reliability

12. FTM directly and indirectly helps you in achieving the above
Key Result Areas
3. Improving the corporate culture
From authoritarian to participative management
Involving everyone in CIP
4. Reducing losses
Down time losses
Speed losses
Defect losses
FTM directly and indirectly helps you in achieving the above

13. Contact Information
Werardt Systemss Pvt Ltd
Pune, India
Phone : ,
Website :