Akhil Bharatiya Maratha Shikshan Parishad's
Anantrao Pawar College of Engineering & Research
Record No.: ADM/D/036B DoI: 21/01/2019
Revision: 00
Internal Correspondence For Department
Answers for Question Banks of Total Quality Control
Unit 5. Total Productive Maintenance
Que.1. Explain the concept of TPM.
Prof.Sandeep V. Raut
Akhil Bharatiya Maratha Shikshan Parishad's
Anantrao Pawar College of Engineering & Research
Record No.: ADM/D/036B DoI: 21/01/2019
Revision: 00
Internal Correspondence For Department
Que. 2 What are the different types of maintenance?
Corrective Maintenance
Corrective maintenance is what you need to do when something breaks; it is better known as
repairs. When a part of the property has ceased to operate properly, it is necessary to do
corrective maintenance.
Some stratas run the property in this manner. This model, called a Run to Fail (RTF) model
means that there are no other types of maintenance done on the property. Problems are only
addressed as things break.
Using this model has few benefits. There is less work to be done on a regular basis, so this
reduces labor costs. It might even reduce the need to have repair staff on site. However, this can
lead to neglect of the property. Parts of the property that are left to fail in this manner can also
Prof.Sandeep V. Raut
Akhil Bharatiya Maratha Shikshan Parishad's
Anantrao Pawar College of Engineering & Research
Record No.: ADM/D/036B DoI: 21/01/2019
Revision: 00
Internal Correspondence For Department
cause damage to secondary systems. Corrective repairs can also be more costly when they need
to be taken care of.
Preventative Maintenance
Preventative Maintenance attempts to spread out the costs by planning activities on a regular
basis. Assets are regularly inspected, cleaned and have adjustments made to them by
knowledgeable staff. Since the maintenance is done on a schedule, assets will be addressed at a
specific time, not when some type of event occurs.
This schedule attempts to head off equipment and asset failures by “preventing” the failures
before they happen. By doing this secondary costs can also be reduced. A well maintained HVAC
system will operate more efficiently and have reduced energy consumption costs than one left
to its own devices.
Preventative maintenance can be labor intensive and might require having on site staff to
perform the duties. While some failures can be prevented by using this schedule, others will
occur regardless of the amount of upkeep that is done. In spite of this, there is a cost savings
potential overall when using this plan over corrective maintenance schedules.
Predictive Maintenance
Predictive maintenance attempts to forecast when an asset is going to fail. This is done by monitoring
the asset and then using the data that is collected to prevent the failure before it occurs. If indications
show that some type of action needs to be taken, say lubrication of an HVAC pump, then that is
performed.
Instead of working on a schedule, maintenance is driven by indications given by the equipment. Some
complex methods can be used to collect data including automatic and computerized reading of data.
Like the previous methodology, predictive maintenance can also keep equipment operating in a more
efficient manner. This method is also less labor intensive than other systems, but carries a more
expensive up front cost.
Que.3.What is Overall Equipment Efficiency?
OEE (Overall Equipment Effectiveness) is the gold standard for measuring manufacturing
productivity. Simply put – it identifies the percentage of manufacturing time that is truly productive.
An OEE score of 100% means you are manufacturing only Good Parts, as fast as possible, with no
Stop Time.
Measuring OEE is a manufacturing best practice. By measuring OEE and the underlying losses,
important insights can be gained on how to systematically improve the manufacturing process. OEE
is an effective metric for identifying losses, bench-marking progress, and improving the productivity
Prof.Sandeep V. Raut
Akhil Bharatiya Maratha Shikshan Parishad's
Anantrao Pawar College of Engineering & Research
Record No.: ADM/D/036B DoI: 21/01/2019
Revision: 00
Internal Correspondence For Department
of manufacturing equipment (i.e., eliminating waste). The best way for reliable OEE monitoring is to
automatically collect all data directly from the machines.
The main purpose of any OEE initiative is to become the most efficient, most effective manufacturer
within a market, minimising the above main losses. A world-class OEE has a benchmark OEE rating
of at least 85%. However, simply maintaining an 85% rating does not guarantee world-class status.
Each component of OEE must meet different levels of individual performance; availability should be
at 90%, performance should be at 95% and quality at 99%. These benchmarks allow manufacturers
to have a point of reference for determining when these components meet acceptable levels.
Automotive Industry
An automotive customer was trying to extract additional productivity out of their assembly line by
improving equipment availability. They had already reduced all known causes of downtime through
diligently applied process engineering steps; they implemented a downtime detection and efficiency
calculation (OEE) system. Within two weeks of implementing the OEE system in the department that
was identified as the plant’s bottleneck area, they noticed that overall productivity was significantly
affected by hundreds of brief line stoppages caused by a simple mechanical misalignment that was
not recorded by operators. By observing these downtimes on the OEE system, it was determined that
the cumulative effect to these brief unscheduled downtimes was the primary cause of downtime in
that department. Without an OEE system automatically detecting all events, these downtimes and
their effects on overall productivity would have gone unnoticed. After process engineers fixed the
alignment problem, the plant was able to produce eight more vehicles per day without adding
resources.
Que.4.What are the different stages of TPM?
PM originated in the Japanese industrial sector. Its aim is to help maintain and improve production
systems. TPM tackles this across a full spectrum, involving all employees at all levels in the
maintenance and servicing of their organization’s equipment and machinery. Applying the principles
properly will help you minimize the likelihood of equipment failures and maximize productivity and
continuity. What’s more, TPM helps raise awareness among employees about technology, safety, and
the environment because it instils a sense of ownership of the equipment and machinery they work
with on a daily basis.
Prof.Sandeep V. Raut
Akhil Bharatiya Maratha Shikshan Parishad's
Anantrao Pawar College of Engineering & Research
Record No.: ADM/D/036B DoI: 21/01/2019
Revision: 00
Internal Correspondence For Department
Step by step to successful TPM.
Step 1: Share your plans with your entire organization
TPM only works if everyone within your organization understands its main objectives and the value
it brings to the table. But above all it’s critical that management and supervisors grasp the importance
of proper TPM procedures. If managers promote, introduce, and adopt a certain way of working, then
shop-floor personnel will generally embrace plans much faster.
Step 2: Identify suitable systems, machinery or processes.
Step 2 involves identifying a suitable part of your working environment where you can conduct a
TPM pilot test. This could be a specific item of machinery or a system, or even part of a production
process that isn’t running particularly smoothly. Pinpoint which elements would give you a quick
win. The SMART method is a useful means for making this selection. SMART stands for specific,
measurable, achievable, realistic, and time-related.
Step 3: Get equipment into optimal working condition.
Step 3 involves getting started with your pilot test. Define the parameters that the equipment or
processes you identified in Step 2 should satisfy. The 5S system is a useful tool for doing this because
it forces you to define the improvements you’re seeking – sort, set, shine, standardize, sustain.
Start by taking photos of the ‘old situation’.
Next, tackle the workspace, removing clutter and any spare parts and tools left lying around. Then,
clean all the machinery and equipment and take a photo of the workspace in the ‘new situation’.
Audits allow you to determine whether staff are keeping workspaces neat and tidy over the longer
term.
Now you have a clearer picture of the equipment and machinery and its current state, you can start
drafting an autonomous maintenance plan. This plan details how to maintain your machinery and
workplace, and clearly defines who does what and when.
Step 4: Measure overall equipment effectiveness.
Step 4 involves measuring and gathering data so that you can start creating an optimally arranged and
efficient production environment. The best way to do this is to use the concept of overall equipment
effectiveness (OEE).OEE tells you how often and how long machinery experiences unexpected
downtime, how frequently faults arise, and what the cost of this downtime or faulty operation is to
your productivity in terms of time, volume, and money. By collecting this data over a longer,
consecutive period (min. two weeks), you’ll be able to identify the bottlenecks and their solutions
more easily.
Prof.Sandeep V. Raut
Akhil Bharatiya Maratha Shikshan Parishad's
Anantrao Pawar College of Engineering & Research
Record No.: ADM/D/036B DoI: 21/01/2019
Revision: 00
Internal Correspondence For Department
Step 5: Identify main losses.
If all went to plan, you now know which items of machinery and processes are operating below par
and are preventing you from hitting your production targets.
This information forms the basis for making focused performance improvements:
Put together a multidisciplinary team to solve the foremost problems. In an ideal situation, this team
should consist of four to six members (operators, technicians, a qualified supervisor) armed with the
highest available expertise, experience, and equipment. Make sure the ‘chemistry’ between individual
team members makes for a good mix.
Schedule structured sessions to solve any outstanding problems. In these sessions, identify the root
cause underlying any processes or environments operating below par and determine the best solution
available.
Using your OEE data, you’ll be able to create a useful schedule for fixing the foremost problems
affecting productivity.
Step 6: Introduce a proactive maintenance program
Now you know what you need to improve, it’s time to introduce a proactive maintenance program
and integrate this with your regular scheduled maintenance program.
Proactive maintenance focuses primarily on the following issues:
Pay particular attention to fragile systems, machinery, or parts and tooling. Keep a logbook
documenting the condition of systems, machinery, parts, and tooling after each inspection. This
allows you to keep track of wear & tear over time and replace parts in time before this causes a
problem. Plan a monthly audit to update your logbook and check that scheduled maintenance is on
track.
Step 7: Embed TPM
This last step involves embedding TPM firmly into your organization’s standard operating
procedures. What’s more, it entails implementing TPM immediately any time you purchase new
machinery or equipment, as this will provide you with a benchmark and concrete data to evaluate its
efficiency and performance levels in the future.
Que.5.Explain in details the pillars of TPM.
1. Focused Improvement
Focused improvement is the first pillar of TPM. The priorities are clear: improve, improve, and
improve continuously. To avoid the loss of equipment, talent, raw materials, and energy, the whole
team must share this vision. The team must be proactive, willing to try new methods, and eager to sit
around the table to work out problems.
Prof.Sandeep V. Raut
Akhil Bharatiya Maratha Shikshan Parishad's
Anantrao Pawar College of Engineering & Research
Record No.: ADM/D/036B DoI: 21/01/2019
Revision: 00
Internal Correspondence For Department
2. Autonomy
Autonomy is the second pillar of TPM, in the sense that every team is an autonomous “maintenance
agent”. Everyone has the autonomy to clean, inspect, and contribute to the upkeep of the assets they
work with. This ensures every piece of equipment is cared for, improves early fault detection, and
frees maintenance technicians for heavier tasks. Learn more about autonomous maintenance and how
to implement it.
3. Quality Maintenance
One of TPM’s biggest goals is manufacturing zero defective products, which, undoubtedly, also plays
into customer satisfaction. Hence, quality management and implementing internal processes linked
to quality control are another pillar. We recommend several root cause analysis tools to root out
problems.
4. Planned Maintenance
Planned maintenance – whether it is planned reactive maintenance or preventive maintenance – is the
best way to avoid downtime and breakdowns. Keep every asset up and running to ensure quality and
avoid customer complaints (for B2C), and improved compliance (for B2B service providers).
Programmed maintenance that requires machines to shut down should be done after regular work
hours.
5. Early Equipment Maintenance
Early equipment maintenance is one of the 8 pillars of a well-succeeded TPM strategy. When it’s
time to choose new equipment or develop new products, consider previous experiences to make
maintenance easier. This can be as simple as choosing a washable paint for the walls (which makes
cleaning easier), or as complex as picking a robot which can self-diagnose malfunctions (which
improves production).
6. Training and Education
TPM requires investing in training and education. Otherwise, it’s impossible to trust each worker
with routine maintenance or prevention. For TPM to work, basic maintenance knowledge about assets
used daily is non-negotiable. Besides, when you think about how fast technology evolves, continuous
training is the only way to make sure your technicians are familiar with new equipment and the state-
of-the-art of the industry.
7. Safety, Health and Environment
TPM also aims at zero work accidents, zero pollution, and zero burnout. Good maintenance
management not only avoids accidents during maintenance activities but also contributes to every
worker’s well-being and safety.
Prof.Sandeep V. Raut
Akhil Bharatiya Maratha Shikshan Parishad's
Anantrao Pawar College of Engineering & Research
Record No.: ADM/D/036B DoI: 21/01/2019
Revision: 00
Internal Correspondence For Department
Estimates suggest about 53% of all cancers in Europe are related to professional activities, usually
due to exposure to asbestos, benzene (used in rubbers, lubricants, dyes, detergents, and pesticides, for
example), chromium, nickel, silica powder (common in mining activities, quarries, glue and paint
factories), radiation and fumes. Proper maintenance of equipment and buildings can help to reduce
these statistics.
8. Office TPM
The last of the 8 pillars is office TPM. This means administrative workers and managers should also
chip in, instead of leaving it to the “worker bees”. Everyone, without exception, must be proactive
and focused on improvements, from logistics to scheduling.
Que.6. Top 5 Challenges in Implementing TPM in any organization.
Any improvement process involves changing the way things are done. Although TPM mplementation
is a positive step for everyone in the organization as it helps grow organisation as a whole, most
organizations face challenges while TPM implementations. We have helped implement TPM in many
organizations and hence would like outline top 5 challenges which every organization face.
1. Lack of Commitment
Top management is the key for success or failure of any TPM implementation. They are influencers
and authority. They drive their team and workforce. It is important that the top management believes
in this methodology and give their 100% to communicate the benefits of the programme and motivate
them to make this programme a success.
2. Resistance to Change
Change is inevitable and only thing which is constant in our life. Any change (good or bad) requires
some effort in changing the way we used to do things before. You will see lot of people in
organisations who would advocate on change and improvement but trust me when it comes to
changing anything in their life, most of them will resist to change. Be it a production manager,
Prof.Sandeep V. Raut
Akhil Bharatiya Maratha Shikshan Parishad's
Anantrao Pawar College of Engineering & Research
Record No.: ADM/D/036B DoI: 21/01/2019
Revision: 00
Internal Correspondence For Department
foreman or any ground level employee who have to change their existing process to bring
improvements in the organization will resist to change.
3. Management see it as a cost centre.
Total Productive Maintenance requires investment in form of time, people, material and money. If
you don’t understand the main objective then it might look like a cost centre instead of a profit centre
to the management.
Let us understand by a simple example:
Let us say that if we have 100 machines in an organisation and 1 engineer to do repair and
maintenance. As machines get older they require regular maintenance to produce quantity and quality.
Even a breakdown of few hours may cost lacs to the organization. Employing a resource who can
maintain machines regularly may only cost a fraction of what an organization may lose at just one
breakdown. If TPM strategy demands an additional resource and Management people who are less
involved in strategy may not understand the importance of that hiring ignore the bigger picture and
hence disapprove the budgets for hiring extra resources and materials. This can be a big roadblock
for successful TPM implementation.
4. Lack of Reward Programme
Any development could only take place when the way of implementation is different from the
traditional one. TPM is such an unconventional methodology which is much progressive. T he
employees are the roots and the pillars of a successful organization but, how often we forget their
contribution. There should be a proper mechanism to reward and appreciate sincere and hardworking
employees, which would motivate them to work with more passion.
5. Lack of TPM Knowledge
TPM is very effective yet a complex mechanism. It is much more than fixing machines and
equipment. In most of the cases, TPM fails due to its incorrect implementation and lack of support
system. Before implementing any innovative process, organisation should run proper training system.
They could learn from the industries where TPM is successfully implemented.
Prof.Sandeep V. Raut
