Timely and effective startup of new products. Flexible response to the demand trend.Reduction in prices.Highlevel quality assurance. Conservation of resources and energy. Timely and effective startup of new products. Flexible response to the demand trend. Reduction in prices. Highlevel quality assurance. Conservation of resources and energy.
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Maintenance
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Zero loss
or Zero tolerance for failure
through People empowerment
© All rights reserved by Gulf Software Consultancy W.L.L.
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Total Productive Maintenance
INTRODUCTION
In the highly competitive world the difference between the winner and the looser is often one hundredth of percentage
This requires perfection and zero tolerance for failure leading to Overall Performance Effectiveness better than the competition.
‘Breakthrough improvement in productivity and reducing chronic losses to zero’
‘Creating a bright, clean, and pleasant factory’
‘Reinforcing people and facilities and through them, the whole organization’
Addressing ‘Overall equipment effectiveness (OEE)’
Institutionalising ‘Total Employees Involvement’, ‘Participative Management’ and an ‘Overall small group organisation’
Eliminating ‘Inter Departmental Walls’ and facilitating ‘Cross Functional Management’
Being material oriented, it seeks to keep equipment in its intended condition
Making possible unmanned operation, factory automation and computer integrated manufacturing
“Lean Production” and “Just-In-Time (JIT)“
“Step by Step approach”
TOTAL PRODUCTIVE MAINTENANCE AIMS
AT:-8 PILLARS OF TPM
Total Employee Involvement
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Total Productive Maintenance
8 PILLARS OF TPM
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Total Productive Maintenance
- JISHU-HOZEN leads to operators maintaining own equipment leading to ownership
- Pleasant work environment
- Happy visitors to plant leads to business
growth
Intangibles
- Improvement proposal increased from 5 to 10
M
- Reduction in accidents to zero
- Reduction in Pollution cases to zero
S
- Reduction in product and work-in-process inventors by half
D
- Reduction in manufacturing cost by 30%
C
- Reduction in defect ratio by 25%
- Reduction in customer complaints by 25%
Q
- Increase in value added productivity
by 1.5 - 2.0 times
- Improvement in Overall equipment efficiency by 150% to 200%
P
Tangibles
Benefits of TPM (As seen in various TPM implementation in companies)
Aiming at “Zero accidents”, ”Zero failures”, and “Zero defects” through introduction of TPM with all
workers participating, which in turn contributes to the improvement of Overall equipment efficiency and reduction in costs
BASIC POLICY
• Reduction in equipment failure 4 Accurate Management of equipment, tools and jigs
• Reduction in waiting and setup time 5 Promotion of resource conversation and energy saving
• Effective use of existing equipment 6 Education and training, cultivation of manpower
OBJECTIVES
TO MEET
• Increase in production and reduction in quality problems
• Equipment deterioration due to overload operation
• Elimination of equipment which has design weak points
• Upgradation of knowledge of equipment control for the operators
• Improve morale of associates
OPERATIONAL DEMANDS
• Timely and effective start-up of new products
• Flexible response to the demand trend
• Reduction in prices
• High-level quality assurance
• Conservation of resources and energy
MARKET DEMANDS
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Total Productive Maintenance
STEPS FOR TPM IMPLEMENTATION
Top Management declaration of TPM initiative.
1
TPM education and awareness
2
Formation of TPM organisation and structure
3
Setting of basic company TPM principles and targets
4
Master plan for TPM implementation
5
Kick-off of TPM company wide
6
Establishing system for improving plant
efficiency
7
Establishing upstream control management for new products and equipments
8
Building quality maintenance system
9
Improvement of administration and commercial function
10
Improvement of safety, health, environment system
11
Complete implementation of TPM
12
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Total Productive Maintenance
✔
✔ Accessing for results
Complete implementation of TPM
✔
✔
Implement by horizontal deployment Company wide of various TPM activities
Regular and continuous training of all people on activity plan Review and monitoring of the activities Corrective action wherever necessary
Implementation & Deployment of TPM activities all over the organisation:
Jishu Hozen OEE / Kobetsu Kaizen Planned Maintenance Training & Skill development Office TPM
Initial Project Management Safety and Environmental Management
✔
✔
Informing the commitment of Top Management to all, including Partners and Customers to TPM
Formal Kick off
✔
✔
Benchmarks and targets for effectiveness of TPM
Making Master plan
Target setting
✔
✔
For department heads and managers to understand & work on
a machine for Jishu Hozen, OEE and Kobetsu Kaizen activities
Selection of Manager Model Machine (MMM)
Start of Jishu Hozen activity in MMM
✔
Control steering for coordinating company wide activity
Departmental committee for coordinating with Control committee and department activity
Formation of TPM
Organisation Committee
Departmental Committee
✔
✔
Top Management: ½ Day Senior Management : 1 Day Managers/ Executives : 3 Days
TPM Awareness
✔
Declaration by Top Management about adopting TPM as major initiative for change
TPM Declaration
Gulf Software Organisation
Responsibility Focusing Point
Process
TPM – PROCESS MAP
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Total Productive Maintenance
SERVICE OFFERED ON TPM
TPM AWARENESS FOR TOP MANAGEMENT
½ Day
Overview on TPM Steps for implementation Role of Top Management in TPM implementation
Contents
To understand TPM philosophy and approach
Purpose
TPM AWARENESS FOR SENIOR MANAGEMENT
1 DAY
TPM steps OEE Autonomous Maintenance overview Role of Senior management in TPM implementation
Contents
To understand TPM philosophy and approach
To understand concept of OEE and its use for management decision making
Purpose
TPM concepts including details of all pillars Use of OEE for improvement and project identification
To understand “Jishu-Hozen” concepts
Contents
To understand the TPM philosophy and approach for "Zero accidents, Zero failures, and Zero defects", and the various pillars for this goal
Purpose
TPM AWARENESS FOR MANAGERS AND SENIOR EXECUTIVES
3 DAYS
TPM PROJECT IMPLEMENTATION
Drawing TPM road-map/master plan for a company
Identifying and providing TPM education and training
Creation of a model machine
Hands on support for making model machine
Deployment of all TPM elements company wide
TPM project monitoring and review
Measurements of benefits planned and achieved
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About Us
For More Information www.gulf software.com
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ABOUT US
Gulf Software and Consultancy is an organisation specialising in the field of TQM Applications We are fast emerging as a center for Knowledge across the Middle East Our wide experience is backed by a highly skilled and totally professional team of consultants who are rated as one of the best in this business today Even though established recently in the year 2005, it is fast emerging as a formidable force to reckon Our team of Consultants have assisted many organizations in their improvement effort for enhancing Business Performance through intervention of different proven tools and
techniques of Six Sigma.
Headquartered at Bahrain, Gulf Software has its spread across the G.C.C countries and presence in select overseas countries as well.
For Additional Information, please contact:
STANDARD PRODUCT DIVISION
Gulf Software and Consultancy
P.O.Box: 11651, Manama, Kingdom of Bahrain Tel: (+973) 17537833, Fax: ( +973) 17537844, Email: gulfsoftware@yahoo.com.