OCTOBER 19-20, 2012 - YMCA University of Science & Technology

Proceedings of the National Conference on
Trends and Advances in Mechanical Engineering,
YMCA University of Science & Technology, Faridabad, Haryana, Oct 19-20, 2012
Table 1. TPM pillars with key activities
Sr. No. Pillars Key activity
1. Autonomous Maintenance
(Jishu Hozen)
It means "Maintaining one's equipment by oneself". There are 7
Steps in & Activities of Jishu Hozen.
2. Focused Improvement
It comprises of continuous improvement even in small steps
(Kobetsu Kaizen)
3. Planned Maintenance It focuses on increasing availability of equipments & reducing
breakdown of machines.
4. Quality Maintenance
(Hinshitsu Hozen)
Quality Maintenance is establishment of machine
conditions that will not allow the occurrence of defects &
control of such conditions is required to sustain Zero Defect.
5. Education & Training Formation a team of workers to performs the
autonomous maintenance activity
6. Initial Control To establish a system of the production for new product &
equipment in a minimum run up time.
7. Safety, Hygiene &
Environment
The main role of SHE (Safety, Hygiene & Environment) is to
create Safe & healthy work place where accidents do not occur,
uncover & improve hazardous areas & do activities that preserve
environment.
8. Office TPM To make an efficient working of office that eliminates losses and
regulate out-put by applying 5’S in office and working areas.
This will also helps in improving synergy between various
business functions and removing procedural hassles with main
focus on cost-related issues.
1.2 Benefits of Office TPM
Office TPM benefits include participation of all people in support functions for focusing on better plant
performance, better utilized work area, reduce repetitive work, reduced administrative costs, reduced inventory
carrying cost, reduction in number of files, productivity of people in support functions, reduction in breakdown
of office equipment, reduction of customer complaints due to logistics, reduction in expenses due to emergency
dispatches/purchases, reduced manpower, and clean and pleasant work environment.
1.3 Literature review
TPM is a strategic approach to improve the performance of maintenance activities which leads effectively and
efficiently working of machines and equipments. TPM seeks to engage all levels and functions in an
organization to maximize the Plant efficiency as well as the effectiveness of production equipment. Some of the
literature on TPM is as follows:
The origin of TPM is traced back to 1951 when Preventive Maintenance was introduced in Japan, described by
Seiichi Nakajima (Known as the father of TPM) [10]. The Japanese has developed TPM to support their lean
manufacturing system based on Preventive Maintenance, Corrective Maintenance and Maintenance Prevention
concepts and methodologies that was originated and developed in the U.S.A. He investigated about the
Equipment Effectiveness (is a measure of the value added to production through equipment). The process of
O.E.E. finding is to increase equipment effectiveness so each piece of equipment can be operated to its full
potential and maintained at that level. Nakajima describes that TPM maximizes equipment effectiveness though
two types of activity to insure that the equipment performs to design specifications, which is the true focus of
TPM. Five key elements for characterizing the TPM are as follows:.
• TPM strives for maximum equipment effectiveness.
• TPM establishes a total system of Preventive Maintenance for the entire life of the equipment.
• TPM includes participation by all sectors of the organization that plan, use, and maintain equipment.
• TPM participation is from top management to the frontline staff.
• Execution of TPM is based on Small Group Activity.
707