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CII INSTITUTE OF QUALITY

39th TPM Facilitators Course- Online

21-25 June 2021

Rahul Kaushik

TPM Club India  Confederation of Indian Industry

 SOP

• After introduction make your video Off & audio on mute condition
• Those who are attending session on mobile should refer training material in
your computer.
• Listen, observe, learn and make notes
• There will be Q&A session after every segment, you should unmute audio.
Questions should be asked one by one, others should be in mute condition.
• You can ask questions during the session also. Unmute audio for it ask.
• There will be few exercises also, instruction will be given at that time
• Keep note book and pen with you to note down the key points, that will be
useful during exam on last day and in future for reference.

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 Program Contents
Day 1: 21st June’21, Monday
• Introduction, Expectation, Agenda & Team Finalization
• TPM Overview & Concept discussion, TPM History, Background,
• Concept of Loss & improving OEE,
• Kobetsu Kaizen Pillar Concept discussion
Day 5: 25th June’21, Friday
•Day 2: 22nd June’21, Tuesday
• Office TPM Concept Discussion and Q&A
• Autonomous Maintenance Pillar Concept discussion,
• Roles & Responsibility of TPM Facilitator
• Q&A
• Closing the loop
• Planned Maintenance Pillar Concept discussion,
• Examination
• Why- Why Analysis explanation and Q&A
Day 3: 23rd June’21, Wednesday
• Quality maintenance Pillar Concept discussion and Q&A
• PM Analysis
• Development Management Pillar Concept discussion and Q&A

Day 4: 24th June’21, Thursday

• Education & Training Pillars Concept discussion and Q&A

• Safety, Hygiene & Environment Pillars Concept discussion

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..

Introduction & Expectation

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..

TPM Overview & Concept discussion

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 Contents

1.What is TPM?

2.Why to Implement TPM?

3.How to develop TPM journey?

4.How do we go about these 8 pillars

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 What is TPM?

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 TPM stands for…

What is TPM? It’s a change management Tool

• T => TOTAL => Employee, Function & Area

Involve in
• P => PRODUCTIVE => Output / Input =>
Production units / Cost

• M => MAINTENANCE => Sustain achieved

condition
To build a culture of Discipline, Challenge, improvement and Innovation

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 History of TPM

1950 1960 1970 1980 1990 2000 2020

BREAKDOWN MAINTENANCE

PREVENTIVE MAINTENANCE

PRODUCTIVE MAINTENANCE

TPM

Mr. Seiichi Nakajima, the Father of TPM COND. BASED MAINT

1919 - 2015
RCM
Nippon Denso
AI
TPM Club India  Confederation of Indian Industry
 Relationship between TPM, Productive Maintenance
& Preventive Maintenance

3 2 1
Autonomous Total System Economic
maintenance (MP-PM-CM) efficiency
by operators (profitable PM)
(small group
activity)

TPM features

Productive
Maintenance
features

Preventive
Maintenance
features

TPM Club India  Confederation of Indian Industry

 Definition of TPM (Companywide TPM)
TPM aims at :

1. Establishing a corporate culture that will maximize production system

effectiveness.

2. Organizing a “genba-genbutsu” system to prevent losses and achieve such

“reduction-to-zero” targets as “zero-accidents”, “zero-defects” and “zero-
breakdowns” in the entire production system life-cycle.

3. Involving all functions of an organization including production, development,

sales and management.

4. Involving every member of an organization, from top management to front-

line operations, and

5. Achieving zero losses through the activities of overlapping small groups.

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 Basic Idea of TPM
1. Making Profitable Company Constitution
- Pursuit of Economical Efficiency, Zero-Accidents, Zero-Defects,
Zero-Failures
2. Philosophy of Prevention (Prevent Accidents from happening)
MP PM CM
3. Participation by All
- Overlapping Small Group Organization, Autonomous
Maintenance by Operators
4. At Plant, In–Process, Gemba (3G)
- Keep the equipment in optimal condition, Visual control, making
a clean workshop (5S)
5. Create a Virtuous Circle of Work place expertise
- Develop a self sustaining, Continuously evolving Self Directed Culture,
Workshop that requires less manpower, Automation, Unmanned Operation
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 Why to Implement TPM?

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 Problems faced by companies
External Factors Internal Factors
• Tough Competition • Productivity low
• Globalization • Customer complaints
• Increase in • Defective products
– Raw material cost • Non - adherence to delivery
– Energy cost time
• Increase in wages and
salaries
• low knowledge and skill level
of workers
• Losses are high

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 Effectiveness Planning
• Turn Over Growth
• Profitability
Key Management Indices (KMI) • Brand
• CSI, ESI

• Productivity
• Quality
• Cost
Key Performance Indices (KPI) • Delivery
• Accident
• Moral

• Themes, projects
Key Activity Indices (KAI) • Circle activities
• Kaizen, OPL, Tags,
• Trainings

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 Effectiveness of TPM

P…..Productivity improvement ----------------------------------------1.5 to 2 times

 Reduction in Number of Equipment Failures --------- 1/10 to 1/250
 Equipment Operating----------------------------------------1.5 to 2 times

Q…..Reduction in Product Defects-----------------------------------0 to 1/10

Reduction in Customer Claims---------------------------------0 to 1/4

C…..Reduction in Manufacturing Cost-------------------------------20 to 50%

Reduction in Maintenance Cost----------------------------------30%

D…..Reduction in Product Inventories--------------------------------0 to 1/10

Customer Delivery Adherence ------------------------------- 100%

S….. Reduction in Accident, Elimination of Pollution--------------0

M…..Increase in Number of Employee Suggestions--------------5 to 10 times
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 Intangible Effectiveness of TPM

1. After introduction of autonomous maintenance activity, operators

take care of machines by themselves without being ordered to.
2. With achievement of zero breakdowns and zero defects,
operators get new confidence in their own abilities.
3. Workplaces that used to be covered with oil and chips are now
so clean and pleasant as to be almost unrecognisable.
4. Improved image of the company, leading to the possibility of
increased orders.

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 Success of few companies

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 Benefits of TPM

INVESTMENT for TPM ACTIVITIES Vs BENEFITS

AMOUNT INVESTED AMOUNT SAVED

1800
1600
1400 1680
1200
LAKHS

1000
800
600 405
400 270
120 120 120
200 30 20
0

AUTOMOBILE SEMI-CONDUCTOR CHEMICAL INDUSTRY PLASTIC PRODUCT

COMPONENT INDUSTRY INDUSTRY
INDUSTRY

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 Certificates and Awards

DIFFERENT LEVEL CII TPM Certificates

 Strong Commitment after one year
 Significant achievement after two years
and
 Excellence in Operational Technology (EOT) Award
after 3 years
DIFFERENT LEVEL JIPM TPM AWARDS
 Excellence Award after 4 years
 Consistency Award after 7 years
 Special Award after 10 years
 Advance Award after 13 years
 World Class Award after 16 years

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 JIPM TPM Award status

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 JIPM TPM Award status

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 How to develop TPM journey?

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 From TPM of Production Department to Company-wide
TPM Covering All Company Activities

Top Management

General
Planning Financial Personnel
Affairs

Administrative

Development of
Sales
products &
Production equipments

Plant Plant Plant Plant

TPM Phase 1
TPM Phase 2

TPM Phase 1 TPM of Production Department

TPM Phase 2 Company-wide TPM encompassing production,
development, sales and administration

TPM Club India Page 24  Confederation of Indian Industry

 12 Steps for TPM Development Programs
Stage Step Essential
Preparations 1. Declaration by top management to introduce TPM Declared in TPM in-house seminar
for Carried in company magazine
introduction 2. Introductory education and campaign for TPM Managers : Trained in seminar camp at each level
General employees : Seminar meeting using slides
3. Establishing TPM promotion organization Committee and subcommittees
Secretary
4. Setting basic principles and target for TPM Bench-mark and target
Prediction of effects
5. Creation of master plan for establishing TPM From preparations for introduction to examination
Beginning of 6. Kick-off of TPM Suppliers
are invited
introduction Related companies
Affiliated companies
7. Establishing systems for improving production efficiency Pursuing maximum efficiency of production
Actual 7.1 Individual improvement Project team activities and small group activities in the workshop
introduction
7.2 Autonomous maintenance Step system, diagnosis and qualification certification
7.3 Planned maintenance Improvement maintenance, periodic maintenance, predictive
maintenance
7.4 Operation and maintenance skills upgrading training Group education of leaders and training members
8. Establishing initial control systems for new products and Development of easy-to-manufacture products and easy-to-operate
equipment equipment
9. Establishing quality maintenance organization Setting conditions without defectives, and its maintenance and control

10. Establishing systems to improve efficiency of administration Support for production, increasing efficiency in the department and of
and other indirect departments equipment
11. Establishing systems to control safety, sanitation and working Establishing zero accidents and zero pollution systems
environments
Steady 12. Total application of TPM and raising its level Application of PM award
application Challenge of a higher target

TPM Club India Page 25  Confederation of Indian Industry

 Typical TPM Organizational Chart
© JIPM, 1993

President
TPM Promotion Office
Company wide TPM
Plant Promotion committee
Manager “Kobetsu-Kaizen”
sub-committee
Plant TPM promotion “Jishu-Hozen”
Section committee sub-committee
Chief Planned maintenance
sub-committee
Section TPM promotion Initial flow control
Sub-
committee sub-committee
Section
Chief “Hinshitsu-Hozen”
sub-committee
Foreman TPM promotion
Office improvement
committee (Leader sub-committee
Supervisor Meeting) Education and training
sub-committee
Small group formed on the
Front-line production floor (PM circle) Safety and hygiene
Worker sub-committee

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 TPM Basic Policy and Example of Target Setting (Example)
Market circumstances In-house circumstances

1. Increase in production and quality trouble

1. Timely and effective start-up of new products 2. Equipment deterioration due to overload operation
2. Flexible response to the demand trend 3. Increase in equipment which has design weak points
3. Reduction in prices 4. Lack of awareness and knowledge of equipment control of the
4. High-level quality assurance operators
5. Conservation of resources and energy-saving 5. Field operators morale depression due to uncertain responsibility
of the operation

Basic Policy
Aiming at “zero-failure”, “zero-defects” and “zero-disaster” through introduction of PM with all workers participating, which in turn contributes to the
improvement of overall equipment efficiency and reduction in costs.

Key points
1. Reduction in equipments failure 4. Accuracy management of equipment, tools and jigs
2. Reduction in waiting and set-up time 5. Promotion of resources conservation and energy-saving
3. Effective use of existing equipment 6. Education and training cultivation of manpower

Target
Actual Actual Target (Target)
record record
1. Reduction in equipment failure 938/Month ----- Less than 10/month
2. Equipment failure rate 1.03%/hundred hours ----- Less than 0.1%/hundred hours
3. Occurrence of equipment failure 1.59% ----- Less than 0.2%
4. Shutdown time 5.800 hours/month ----- Less than 1200 hours/ month (1/5)
Apply for PM
5. Overall equipment efficiency 88.8% ----- More than 95.0% Excellent
6. Improvement of productivity 11.3% ----- More than 169%
award in order
7. Reduction of rework and quality defects from 0.7% ----- (50% increase)
Less than 0.1% to have the
process ----- Less than 70% results of TPM
8. Energy saving 100% (Second half of 1983) ----- (Second half of 1985) activities
9. Number of Kaizen employees suggestions 2.1/year/employee (1983) ----- 60/year/employee evaluated

10. Labour accidents 11/year ----- 0/year

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 TPM Master plan (Example)
Year 86 87 88 89 90
Items to Introduction Implementation stage Full development Steady application
be promoted stage stage stage
Establishment promotion organisation, overlapping small groups in an PM award
hierarchical system & promotion secretariat Screening
Outline Set Policy Target, Slogan, and Achievement goal
Work out master plan

“Jishu-Hozen”
Introductory period (Announcement of introduction made April 1, 1986)

Step 1 Step 2 Step 3 Step 4 Step 5,6 & 7

activities by
Step 7 development Education to transfer the general inspection method
production
department Promotion activities (TPM news, contest using Activities status board, Presentation of activities, etc.
TPM Kickoff (November 27, 1986)

“Kobetsu-Kaizen” Overall equipment efficiency 1.5 times improvement plan

(Elimination of Organisation of KAIZEN teams

losses) Selection of KAIZEN theme

KAIZEN activities (prior development of pilot model Horizontal replication

Establish the planned

Classification of major items, time-based maintenance, Predictive maintenance
maintenance system
Planned Lubrication and spare parts control system (Prior development of pilot model
maintenance
Horizontal application
(Zero-failure) Equipment zero-failure campaign (Prior development of pilot model Horizontal replication

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 TPM Master plan (Example) (Contd.)
Year 86 87 88 89 90

Introduction stage Implementation stage Full development stage Steady application stage
Items to be promoted

Product : Establishing the initial production and flow control system Trial Development

Initial production and flow control Accumulation and utilization of information

Launching the equipment with a Establishing the initial production and flow control
minimum run-up-time Equipment : Development
system and standardization
Trial Collection and application of MP information
Introductory period (Announcement of introduction made April, 1986

Countermeasures against Counter- KAIZEN

Matrix 3M analysis FME, PM Analysis
TPM Kickoff (November 27, 1986

“fuguai” chart measures standardization

“ Hinshitsu-Hozen” <Horizontal development>
(Zero-defect) Countermeasures against Counter-
Matrix 3M analysis “fuguai” chart
FME, PM Analysis KAIZEN standardization
measures

Step 1 Step 2 Step 3 Step 4 Step 5

Development of 5 steps in office operation improvement Development of 4 steps in warehouse and storage management
Office operation improvement
Simplification of accounting-related procedures KAIZEN of production management system

“Sawayaka” campaign

Support for “Jishu-Hozen” activities

Safety management activities Central safety inspection manual Safety general inspection
(zero labor accident)
Daily safety management activities

Education and training (fostering Establishing education system Individual ability development
the operators who are proficient in
equipment operations and Maintenance skill training
maintenance)
© JIPM, 1987

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 What TPM Aims at

To restructure the corporate culture through improvement of human

resources and plant equipment
Improving - Educate and foster employees so that they can respond to the
human needs of FA (Factory Automation) –
resources (1) Operator : Ability to perform “Jishu-Hozen”
(2) Maintenance man : Ability to perform high-quality
maintenance
(3) Production engineer : Ability to execute maintenance- free
equipment plan

Improving (1) Attain efficiency through revamping of the existing equipment

Plant (2) LCC (Life Cycle Cost) – considered design of new equipment
equipment and minimizing their run-up time

Improving the corporate culture

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 Relationship between “Input” and "Output”
in Production Activities
Input Money
Output
Man Machine Material Technique
Production Production
Control
Quality
Quality
Control

Cost Cost
Control

Delivery Delivery
Control

Safety &
Safety Pollution

Morale Human
Relation

Output Output
= Productivity
Manpower Plant Eng. Inventory Input
Management & Control Ultimate Goal of
Method Maintenance Plant Operations
© JIPM, 1987

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 How do we go about these 8 pillars?

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 5 Principles in TPM Development

1. Establish the system to achieve production efficiency.

1.1 “Kobetsu-Kaizen”
1.2 “Jishu-Hozen”
1.3 Planned maintenance
1.4 Education and training for operation and
maintenance skill upgrade

2. Establish initial production and flow control system for new

products and equipment.

3. Establish the “Hinshitsu-Hozen” system.

4. Establish the system to realize operation efficiency in the

administration department.

5. Establish safety, hygiene and working environment protection

systems. JIPM 1987
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TPM Club India
Individual Improvement
(Kobetsu Kaizen)

Autonomous Maintenance
(Jishu Hozen)

Planned Maintenance
(Keikaku Hozen)

Quality Maintenance
(Hinshitsu Hozen)

Page 34
TPM

5S – Workplace Management Development Management

TPM 8 Pillar Approach

Safety, Health &

Environment

Office TPM
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 8 Activities and Loss

KOBETSU
KAIZEN
SAFETY, HYGIENE, JISHU HOZEN
ENVIRONMENT

OFFICE LOSS
PLANNED
TPM MAINTENANCE

EDUCATION &
QUALITY TRAINING
MAINTENANCE
DEVELOPMENT
MANAGEMENT

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 Focused/ Individual Improvement

Purpose:
• Demonstrate ultimate production efficiency improvement – P & C targets
• Realize zero losses of all types, such as failure losses and defect losses

Activities:
• Understanding the 16 major losses
• Calculating and settling goals for overall equipment efficiency, productivity and
production subsidiary resources
• Select themes for Improvement
• Make Teams for each theme
• Set Targets and timeline for projects
• Review the teams progress
• Follow PDCA

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 Autonomous Maintenance

Purpose:
• Engaging operators in improvement journey and boost their Morale
• Training of operators to make them proficient
• Ownership development

Activities:
Implementation of 7 steps
1. Initial clean-up
2. Countermeasures for the source of problems and measures for difficult-to- access
locations
3. Creation of tentative autonomous maintenance standards
4. General inspection
5. Autonomous inspection
6. Standardization
7. All-out goals management

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 Planned Maintenance

Purpose:
• Achieve and sustain zero breakdown in equipment
• Improve maintenance efficiency to reduce cost prevent other major losses

Activities:
• Daily Maintenance
• Time Based Maintenance
• Condition Based Maintenance
• Improvement for increasing the service life expectancy
• Control of replacement parts
• Failure analysis and prevention of recurrence.
• Lubrication control
• Maintenance Skill development

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 Quality Maintenance

Purpose:
• Achieve and sustain zero product defects conditions

Activities:
• Verify quality characteristics standards; understand defect phenomena and
performance
• Investigate the conditions for building in quality, unit processes and raw materials,
equipment and methods
• Investigate, analyze and improve the conditions of malfunctions
• Setting 4M conditions; setting standard values for inspection
• Creation of standards that can be followed; trend management
• Implementation of PM analysis
• Thorough pursuit of equipment and production “as it should be”.

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 Education and Training

Purpose:
• Enhance Employees Competency and Morale
• Establishment of technical education system for operations and maintenance
workers

Activities:
• Set standards for knowledge & skill for each position in the plant
• Evaluate existing knowledge & skill of each employees and find gap between
required and actual
• Establish system for training and train employees to achieve required skill
• Few examples of training module: Basic process of maintenance
• Tightening nuts and bolts, Aligning keys, Maintenance of bearings, leaks prevention
• Maintenance of oil pressure and air pressure equipment
• Maintenance of conductive parts
• Maintenance of electrical control equipment

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 Development Management

Purpose:
• Reduction in product development, prototyping and mass production time
• Reduction in equipment development, design, fabrication and installation time
• Improve 1-shot start-up stability of products and equipment, First time right

Activities:
• Setting development and design goals
• Ease of production
• Ease of QA Implementation
• Ease of use
Reflect in MP design
• Ease of maintenance
• Reliability
• Investigate LCC
• Design release drawing
• Identify problems in the prototype, trial run and initial-phase mass production
control stages to make next product first time right in less time.

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 Office TPM

Purpose:
• Creation of efficient offices
• Achieve zero function losses
• Implementation of service support functions for production departments
Activities:
• Autonomous maintenance activities
1. Initial clean-up (personal space)
2. Work inventory
3. Countermeasure for problems
4. Standardization
5. Promotion of autonomous management activities of work
• Individual improvement through project activities
1. Shortening of settlement schedule
2. Improvement of distribution
3. Improvement of purchasing and subcontracting
4. Reform of production control system • Skill enhancement of Office people
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 Safety, Health and Environment

Purpose:
• Achieve and sustain zero Accident, Health hazard and pollution
• Realization of a healthy and invigorating workplace that makes exciting work place

Activities:
• Measures to prevent accident
• Measures to improve equipment safety
• Measures to improve work safety
• Improvement of work environment (noise, vibration and odors)
• Measures to prevent pollution
• Creation of healthy employees
• Promotion of invigorating activities

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information

www.tpmclubindia.org

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