(NU Reg. No.- 111291 of 2011-2012) Course : MGT 401 Total Quality Management Course Instructor : Mr. Hriyo Kayina Date/ Time : April 17, 2013/ 0900 hr M M X I I I - M M I V School of Management Studies Nagaland University CONTENT School of Management Studies, Nagaland University 1.1 TPM An Introduction 1.2 Objectives of TPM 1.3 Wastes Eliminated in TPM 1.4 Equipment Maintenance Techniques Reference 1.5 Benefits of TPM 1.6 Performance Measures of Maintenance System 1.7 VIII Pillars of TPM 1.8 Conclusion Important This topic is covered under UNIT V of MGT 401 TQM, NU MBA Old syllabus. While discussing 8 Pillars of TPM follow the sequence ! Its coming in exam so pay attention!
School of Management Studies, Nagaland University 1.1 TPM An Introduction School of Management Studies, Nagaland University TPM Optimize Productivity All Levels of Employees Management System Seiichi Nakajima Institute of Plant Management, Japan 50s Repair after breakdown Productive Maintenance 70s 1.2 Objectives of TPM School of Management Studies, Nagaland University Why TPM was launched? Create a Collective culture Maximum Efficiency Accidents Defects Breakdowns Losses 0 1.3 Waste Eliminated in TPM School of Management Studies, Nagaland University Break Down Setup/ Changeovers Idling/ Minor Stopover Reduced Eqpt. Speed Defects & Rework Start-up 6 Big Losses 1.4 Equipment Maintenance Techniques School of Management Studies, Nagaland University Preventive Maintenance Corrective Maintenance Time Based Maintenance Predictive Maintenance Maintenance prevention Break down Maintenance 1.5 Performance Measures of Maintenance System School of Management Studies, Nagaland University OEE % =uptime % x Speed % x Quality % Uptime % = (MTBF-MTTR) X 100 MTBF MTBF = Total Running Time
No. of failures Speed (%) Efficiency = Actual cycle time X 100 Design cycle time Quality (%) Efficiency = Good parts produced X 100 Total parts produced 1.6 The 8 Pillars of TPM School of Management Studies, Nagaland University
TPM VII Pillars 5 S
J i s h u
H o z e n
K a i z e n
P l a n n e d
M a i n t e n a n c e
Q u a l i t y
M a i n t e n a n c e
T r a i n i n g
O f f i c e
T P M
S a f e t y ,
H e a l t h
&
E n v i r o n m e n t
1.6.1 5 S School of Management Studies, Nagaland University 5 S 1. SEIRI (Sort out) 5. SHITSUKE (Self-discipline) 2. SEITON (Organise) 3. SEISO (Shine the work place) 4. SEIKETSU (Standardization) 1.6.2 Jishu Hozen (Autonomous maintenance) School of Management Studies, Nagaland University Purpose Prepare the operators to take care of routine maintenance tasks Steps in JH 1. Preparation of employees 2. Initial clean-up 3. Taking counter measures for the inaccessible areas of the machine 4. Fixing tentative JH standards 5. General inspection training for employees 6. Autonomous inspection 7. Standardization 8. Achieve OPE and OEE and other TPM targets through Kaizen 1.6.3 Kaizen School of Management Studies, Nagaland University Meaning Change for better Focus Foundation (5 Elements) 1. Team work, 2. Personnel discipline, 3. Improved morale, 4. Quality Circles 5. Suggestions for improvement Philosophy Incremental Change 1. Zero losses 2. Cost reduction in all resources 3. Improvement of overall plant effectiveness 4. Use of PM analysis 5. Easy handling of operators 6. 30% manufacturing cost reduction Losses Impede equipment efficiency Impede human work efficiency Impede effective use of production resources. 1.6.4 Planned Maintenance School of Management Studies, Nagaland University Purpose Have trouble free machines/ equipment to produce defect free products Steps in Planned Maintenance 1. Evaluate equipment and record its present status. 2. Restore from deterioration of equipment and minimize its weaknesses. 3. Build up information management system. 4. Prepare time based information system, select equipement parts and memebers and map out plan. 5. Prepare predictive maintenance 6. Evaluate planned maintenance. Types Preventive Maintenance Corrective Maintenance Maintenance Prevention Breakdown Maintenance 1.6.5 Quality maintenance School of Management Studies, Nagaland University Purpose Educating operators to upgrade their skill Focus 1. Focus on improvement of knowledge, skills and techniques. 2. Creating a training environment for self-learning based on felt needs. 3. Training curriculum/ tools/ assessment, etc. conductive to employee revitalization. 4. Training to remove employees fatigue and make work enjoyable. 1.6.8 Safety, health and environment School of Management Studies, Nagaland University Purpose Have zero accident, zero health damage and zero fires How to achieve? Creating a safe work place Creating a surrounding area that is not damaged by the processes and procedures. Creating awareness among employees Conclusion Develop a globally competitive Industrial Base in our State (Nagaland) and NER School of Management Studies, Nagaland University Our Mission 1. We must Learn, Adopt, Adapt and Deploy TPM in our Conditions and as per our needs 2. We must Strive for Excellence in the Working methods/ style needed Excellence in the quality of our Products Excellence in the quality of our Services References Panneerselvam, R. Production and Operations Management, 2 nd Edition, PHI (2010) MS 96 Total Quality Management, IGNOU
School of Management Studies, Nagaland University End of Presentation School of Management Studies, Nagaland University And I am open to queries