Pdf developing total productive maintenance model tpm for. Quality and maintenance of manufacturing systems are closely related functions of any organization. It was a systematic approach to help companies achieve zero breakdown, zero defects, and zero. Pdf in this research a developed tpm ladder model is presented, this. This thesis describes the application of total productive maintenance tpm tools and techniques to identify the losses and to reduce them on priority basis to. The goal of the tpm program is to markedly increase production while, at the same time, increasing employee. The relationship between lean and tpm mohammad reza enaghani. This paper presents a brief action plan for implementation of total productive maintenance tpm. The impact of total productive maintenance practices on manufacturing performance through secsgem standard for electronic contract manufacturing companies krishnamoorthy renganathan a thesis submitted in full fulfillment of the requirements for the degree of doctor of philosophy business administration centre for graduate studies. The start value for the thesis goals proved to be overestimated, with the actual initial value at 115 produced units per hour and employee.
Total productive maintenance is a maintenance philosophy, but there are tangible kpis that accompany it. Tpm, however, stands for total productive maintenance, or productive maintenance with total participation. Phd thesis, an assessment of total productive maintenance tpm. Achieving 100 percent reliability takes discipline and teamwork. The impact of total productive maintenance practices on manufacturing performance through secsgem standard for electronic contract manufacturing companies krishnamoorthy renganathan a thesis submitted in full fulfillment of the requirements for the degree of doctor of philosophy business administration centre for graduate. Index term total productive maintenance, performance.
A methodology for implementing total productive maintenance in the commercial aircraft industry. Tech production, 2assistant professor, 3student, m. Total productive maintenance tpm is a maintenance program which involves a newly defined concept for maintaining production plants and equipment. The maintenance role of reducing downtime impacts not highly recognized. The thesis titled implementation of autonomous maintenance and kaizen to enhance overall equipment efficiency in an apparel manufacturing unit submitted by md. First developed in japan, tpm is teambased productive maintenance and involves every level and function in the organisation, from top executives to the production floor operators.
Total productive maintenance, lean manufacturing, eksamo as, 5s, overall equipment effectivene, industrial robot. A systematic maintenance approach for some chinese companies was urgently needed. Pdf total productive maintenance tpm implementation in. Massachusetts institute of technology, sloan school of management, 1996, and thesis m. The main objective of this research was to find the best strategy to improve the performance of tpm through the autonomous. Worlds largest firms strive to adopt the maintenance strategies to achieve the firms goals and objective that is increased production etiennehamilton, 1994. Moreover, background theory discusses the total productive maintenance and process improvement. The initiation of tpm to a pilot production line in the german automobile industry. Total productive maintenance tpm concepts and literature. An introduction to total productive maintenance tpm by venkatesh j what is total productive maintenance tpm.
From an empirical study, conducted by these authors, it is revealed that demanding quality in maintenance practices is still a far cry. The concept of total productive maintenance tpm has been introduced and developed by japanese in 1971. At the same time, the lack of maintenance standards affects equipment maintenance. Total productive maintenance increasing efficiency. This came in response to the maintenance and support problems in commercial factory. Total productive maintenance tpm concentrates on productivity improvement, primarily by way of maximizing the availability of equipment. School of engineering this thesis is a compulsory part in the master of science with a major in industrial engineering quality and environmental management.
Total productive maintenance, warehousing, reliability. After reading you will understand the basics of this powerful quality and process management method what is total productive maintenance tpm. Total productive maintenance tpm implementation in a. Keywords total productive maintenance, innovative performance, automotive. Dale manchester school of management, umist, manchester, uk keywords total productive maintenance, implementation, organizational structure abstract this paper focuses on a study of total productive maintenance tpm in three companies.
A study of total productive maintenance implementation f. A case study on total productive maintenance in rolling mill chetan s sethia1, prof. As an integral approach to business solutions tpm total productive maintenance is a core support programme affiliated with the japanese institute of plan maintenance jipm, considered to be the global leading body, tpm is not just a professional maintenance approach but. Tpm total productive maintenance the big idea getting operators involved in maintaining their own equipment, and emphasizing proactive and preventive maintenance will lay a foundation for improved production fewer breakdowns, stops, and defects. Over a period of time two concepts have emerged which are total productive maintenance tpm and total quality management tqm along with other concepts. If the same improvement rate of 14% was to be applied to. Although this thesis is about total productive maintenance, the ideology of lean manufacturing. Total productive maintenance tpm is a maintenance program, which involves a newly defined concept for maintaining plants and equipment. Pdf in this research a developed tpm ladder model is presented. Implementation of total productive maintenance on haldex.
Tpm was first applied by the japanese company nippondenso. An introduction to total productive maintenance tpm. Implementation of total productive maintenance in thermal. A study of total productive maintenance implementation. The initiation of total productive maintenance to a pilot production.
This article explains the total productive maintenance tpm in a practical way. Eb762001 author ebrahim, mohammed jawad title total productive maintenance tpm in the power industry. The empirical section is qualitative research based on implementation of choosed method. The goal of the tpm program is to markedly increase production while, at the same. Implementation of autonomous maintenance and kaizen to. Evolved in japan since 70s from toyota for companies who desperately want to win in todays competition. The total productive maintenance tpm concept provides a quantitative metricoverall equipment effectiveness oee, for measuring the effectiveness of. In this study, total productive maintenance in sappi kraftngodwana mill and sabmillerpolokwane brewery is researched to ascertain the effectiveness of the tpm program. Sappi kraftngodwana is a paper manufacturing company. Total productive maintenance tpm is a system of maintaining and improving the integrity of production, safety and quality systems through the machines, equipment, processes, and employees that add business value to an organization tpm focuses on keeping all equipment in top working condition to avoid breakdowns and delays in manufacturing processes.
Furthermore, the same analysis shows the requirement for better results of performance measurement systems is by implementing total equipment. The goal of the tpm program is to markedly increase production while, at the same time, increasing employee morale and job satisfaction. Total productive maintenance was suitable for this current situation. An analysis of maintenance strategies and development of a. Almost all industrial production processes are carried out with the aid of machines, as a result of which each productionoriented organization is largely dependent on. Total productive maintenance tpm is a maintenance program which involves a newly defined concept for maintaining plants and equipment.
This master thesis constitutes the final task of my masters education in management business. The introduction of tpm at borealis stenungsund towards a worldclass maintenance masters thesis in production engineering peter. This was the first book in english on total productive maintenance tpm a system which has been shown to reduce breakdowns to almost zero and increase worker. In total productive maintenance, reliability and availability are the ultimate goals and the way to. Introduction to total productive maintenance by seiichi. It was developed in japan in the 1960s, but has been adapted over time to center on those who operate the equipment. Later the method was further developed by the japan institute for plant. Implementation of total productive maintenance tpm digikogu. The goal of the tpm program is to markedly increase production while at the same time increasing employee morale and job satisfaction. Importance of total productive maintenance engineering essay. Pdf total productive maintenance and innovation performance in.
Implementation of total productive maintenance in thermal power station barauni refinery. The impact of total productive maintenance on the manufacturing sector by i. Total productive maintenance is a concept which aims at zero down time. Tech production department of mechanical engineering, yeshwantrao chavan. This master thesis is aimed to the maintenance department and will thus not focus or take into. The areas of interest in this masters thesis aretpm. A case study on total productive maintenance in rolling mill. It is teambased preventive and productive maintenance and involves every level, from top executive to the floor operator. Implementing successful total productive maintenance tpm. Implementation of total productive maintenance and overall.
The total productive maintenance pillars constituting tpm3 ross, 2006. Total productive maintenance and the basic pillars of tpm. To do that, small multidisciplinary teams improve stepbystep the overall equipment effectiveness of their production lines. This bachelors thesis was commissioned by kennametal widia gbmh. Total productive maintenance tpm is a unique approach to equipment maintenance. Total productive maintenance tpm summary of tpm tpm was developed in the 1970s as a method of involving machine operators in the preventive maintenance of their machines a reaction to increasing specialization and centralization of the maintenance function that had created divisionoflabor barriers between operators and the maintenance of. Dear ladys and gentleman, this is a survey about the topic total productive maintenance tpm. One of the most important measurements of total productive maintenance is overall equipment effectiveness oee, which measures availability, performance efficiency, and quality.
Total productive maintenance tpm is widely used as maintenance tool in manufacturing process and it is defined as such productive activities that are implemented by all employees. Total productive maintenance tpm is a maintenance concept that aims not only to improve productivity but also to improve morale and workers responsibilities to do they own job. Implementing successful total productive maintenance tpm in a manufacturing plant ignatio madanhire, and charles mbohwa abstract this study examines the impact of total productive maintenance tpm implementation on an organization in terms of productivity and quality levels. The case study of total productive maintenance implementation focused on its implementation, in three different companies. Organizations that want to compete and become world class need to successfully implement total productive maintenance tpm programs.
An analysis of maintenance strategies and development of a model for strategy formulation. Maintenance steven borris mcgrawhill new york chicago san francisco lisbon london madrid mexico city milan new delhi san juan seoul singapore sydney toronto. Action plans in implementation of total productive maintenance. Tpm concept and implementation approach sorabh gupta a, p.
Studying the requirements of tpm total productive maintenance in production system. Tpm improves equipment effectiveness lean production. The present paper deals with the concept, introduction and implementation approach of total productive maintenance tpm in detail. Tewari b, avadhesh kumar sharma c a department of mechanical engineering, haryana engineering college, jagadhri, haryana, india. It can be considered as the medical science of machines. Pdf studying the requirements of tpm total productive. I dedicate this thesis to my parents, junmin sun and caili zhu, who are a great. Target of the survey is to evaluate the degree of realization of tpm in your production site and is part of my master thesis at the management center innsbruck. In industry, total productive maintenance is a system of maintaining and improving the integrity of production, safety and quality systems through the machines, equipment, processes, and employees that add business value to an organization. A thesis submitted in full fulfillment of the requirements for the degree of. An introduction to total productive maintenance essay.
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