tpm or the total productive maintenance helps in achieving zero accidents
zero breakdown and zero defects so if you're not utilizing tpm in your company this could
be a solution to move forward towards this goal of zero defects zero accidents and zero breakdown
so in this video i'm going to cover what is tpm or what is the origin history behind this tv
how it is structured or what we known as the eight pillars of tpm what is the difference between tpm
and tqm where we normally get confused what are the different types of maintenance whether
it is corrective maintenance or the preventive maintenance and why should we implement tpm or
what are the typical benefits of implementing this tpm you can also participate by answering three
simple questions for for that uh just leave your comments or answers in the comment section below
the tpm is basically an acronym where t stands for total that is all the individuals in the
organization working towards a common goal and p stands for productive that is producing goods that
meets or exceeds the customer expectations and m stands for maintenance that is keeping equipment
and the plant in good condition all the time so in a perfect world machines would never break down
assembly lines would never stop superior product will be produced without the effect product will
always meet the customer expectation but unfortunately in non-non-perfect world
some things might happen that will throw the production off schedule that is why this tpm
comes into picture the main objective of tpm is to increase the overall equipment effectiveness
that is oee which is the primary metric to gauge the tpm performance the goal of tpm is to drive
the waste to zero that is zero accidents zero breakdowns zero defects and zero waste on its
surface this may seems impossible but if it is possible for run to run for one hour then
why cannot be it be done for five hours for 24 day hours for five days for entire shift
and so on origin and the history of tpm so before we start the origin in case if you're watching my
channel for the first time make sure you hit the subscribe button and do hit that bell icon so that
you are notified whenever i publish a new video on my youtube channel so the origin of tpm can
be traced back to 1951 when the preventive maintenance was first introduced in japan
however the concept of preventive maintenance was taken from the united states of america
the first use of tpm was in japanese automotive company named nippo denso where
the company's improvement theme was the productive maintenance with the total employees participation
the company name was further changed from nippo denso to denso removing the nippon
so the tpm arises from the preventive maintenance and the shortcomings of tqm
in the maintenance aspect the need to go further than the preventive maintenance was quickly
recognized with those companies who were committed to tqm at that point of time the first question
is the total in the total productive maintenance refers to all the individuals in the maintenance
and the production working together so is this a true statement or a false statement or are
you going to say anything about this statement leave your answers in the comment section below
eight pillars of tpm just like the physical structure starts with the grounded framework
building a strong tpm process requires strong foundation in the form of 5s the goal of 5st
is to create a work environment that is clean and well organized so if you want to know more about
what is 5s you can check out this video in the i button and i will also share the link in the
description below the 8 pillars are built on this foundation of 5s the first pillar that we have is
autonomous maintenance that is the maintenance task and caring for the equipment so start
with people who actually using the equipment such as cleaning lubricating and inspection
what it does is it gives operators a greater ownership of their equipment it increases
operators knowledge of their equipment ensures the equipment is well cleaned and lubricated
it identifies emergent issues before they actually cause any failure the next pillar that we have
is planned maintenance so plant maintenance activities are essential on the prevention
of equipment breakdown plant maintenance is performed by periodically evaluating
the condition of equipment to proactively prevent deterioration and mechanical failure
so what it does is significantly reduces the instance of unplanned stop time it also enables
most maintenance to be planned for a time when equipment is not scheduled for any production
the next pillar is quality maintenance to ensure the satisfaction of customer manufacturing
process come for zero defect process the goal of quality maintenance is to identify any possible
cause of deviation from zero defect production so what it does is it reduces the number of defects
reduces the cost by catching the defects the next pillar is focus improvement so having a
small group of employees work together proactively to achieve a regular incremental improvement in
the equipment operations what it does is it includes recurring problems are identified
and resolved by cross-functional teams the next pillar is early equipment management that is the
directly practical knowledge and understanding of manufacturing equipments gained through tpm
towards improving the design of a new equipment what it does is the new equipment reaches the
planned performance level much faster due to the fewer startup issues and the maintenance is
simpler and more robust due to the practical review and of employees involvement prior
to installation the next pillar is training and education so the idea behind tpm is that everyone
does their part to contribute to the overall productivity of a production process in order to
achieve the optimum performance and to build each member's competence proper training is required
next pillar is the safety health and environment it focuses on creating a safe workplace
the essence of this pillar is recognized when actively applied to each of the other pillars
the last pillar is the tpm in the administration a key role that is often overlooked is the
administration department that works behind the scenes like the rest of the production team
and process management and the administration functions are also subjected to the productivity
improvement so these are the eight pillars on which our tpm are built question number two
which of the following is not an interpretation of the term perfect production options are production
without any breakdown production without any defects production without any accidents
or production with hundred percent error you can leave your answers in the comment section below
now let us see the difference between tpm and tqm so both these dpm and tqm are the key operation
activities of quality management system if you talk about the difference between these two
so tpm is more focused on equipment that is the input parameter while tqm is more focused on the
overall quality as output tpm is basically aims to eliminate losses and weighs totally that is
the zero defect approach while tqm aims to reach incredible quality level that is the
defects per million opportunities tpm is related to employees participation and hardware oriented
while tqm is related to systemizing the management and the software oriented
even though these are some of the differences but they do have some common goal
that is avoid waste in the fast-paced environment producing quality goods
consistently reduced cost and minimizing the defect and increases the overall quality
question three tqm focuses on and the tpm focuses on so options are equipment and quality
both on equipment quality and equipment and both on quality you can leave your
answers in the comment section below now let us understand the different types of maintenance here
broadly there are two types of maintenance corrective maintenance and preventive maintenance
corrective maintenance is implemented right after the defect has been detected on the piece of
equipment or the production line its objective is to make the piece of equipment work normal again
so that it can perform its assigned function corrective maintenance are basically of two
types immediate maintenance and deferred maintenance so immediate maintenance is
something which is performed as soon as the failures occur or degradation is detected this
minimizes the downtime and focuses on getting the equipment back in the perfect working condition
as soon as possible on the other hand the deferred maintenance is a practice of
postponing the maintenance activities such as repair in order to save some time and cost
so that is corrective maintenance the other type of materials that we have is the preventive
maintenance so preventive maintenance is aimed at catching or fixing the problems before they happen
it is mostly commonly carried out in the form of regular inspections
usually occurring multiple times per year the primary benefit of this preventive maintenance
is that it can emulate unplanned shutdown time as you early catch the problems beforehand
preventive maintenance are basically of two categories condition based and predetermined so
condition base is something which is considered as a more advanced alternative to preventive
maintenance rather being being inspected according to the schedule machines and system are carefully
observed for changes that could trigger the upcoming failure the other type of is the predator
mind that is a less known of all the maintenance and does not rely on the equipment actual state
but rather on the program delivered by the manufacturer they elaborate this background
based on the failure mechanisms as well as on the mttf that is mean time to failure
tpm typically has many benefits which is why implementing people is certainly worth considering
so before we look at the benefits don't forget to share this video with all your friends and
colleagues and if you have any specific comments or suggestions do let me know in that comment
section below so the first benefit that we have is unplanned less unplanned maintenance so when tpm
is properly implemented it can reduce unplanned maintenance because it introduces more structured
approach to maintenance and encourages a sense of ownership among the operators
using your equipments and machinery less downtime because tpm introduces ongoing and structured
quality process procedure your machinery will be less affected by the downtime or faults
safe work environment because tpm also addresses human issues it leads to safe work environment
employees are expected to keep their workpiece neat clean and tidy lower production cost so
that means the fault or the broken machinery and equipment cost money so when the tpm increases the
efficiency of a machinery it also helps to reduce your maintenance and the production cost thereby
increasing the profitability next we have is the measurable results another important benefit are
the tangible measurable results the parameter to measure the tpm is the oee that is overall
equipment effectiveness the last that is not but not the least it helps in reducing the number of
accidents