“Total Quality Management”

TOPIC: 8 Pillars of TPM

Submitted to:

Ma’am kanwal Kiran

Submitted by:

Fajar Noor e Sehr (02)

Student of Bachelor of Business Administration

SESSION (2023-2027)

DEPARTMENT OF BUSINESS ADMINISTRATION

GOVERNMENT COLLEGE AND WOMEN UNIVERSITY

SIALKOT
 “8 Pillars of TPM”
Total Productive Maintenance (TPM) is a systematic approach to improve equipment
effectiveness, reduce breakdowns, and involve all employees in maintenance activities. The
TPM system is built on 8 pillars, each focusing on a specific improvement area.

1. Autonomous Maintenance:
Autonomous Maintenance empowers machine operators to take responsibility for basic
maintenance of their equipment.
Steps:
 Initial Cleaning of Machines:
Operators clean machines thoroughly to understand their condition and identify
abnormalities.
 Eliminating Sources of Contamination:
Dust, oil leaks, and waste sources are removed to keep machines clean and reliable.
 Establishing Cleaning and Lubrication Standards:
Standard procedures are created for regular cleaning and lubrication to maintain
machine health.
 Routine Inspection by Operators:
Operators inspect machines daily to detect early signs of wear or damage.
 Operator Training for Minor Maintenance:
Operators are trained to perform simple maintenance tasks like tightening bolts and
replacing parts.
 Continuous Improvement by Operators:
Operators suggest improvements to reduce failures and improve machine performance.
Tools:
 5S (Sort, Set in Order, Shine, Standardize, Sustain):
Helps maintain cleanliness, organization, and discipline at the workplace.
 Checklists:
Used by operators to ensure all maintenance tasks are completed regularly.
 Visual Controls:
Labels, color markings, and signs help quickly identify machine conditions.
 Lubrication Charts:
Show when, where, and how much lubrication is required for machine parts.
Example:
In a manufacturing plant, machine operators clean their machines daily, check oil levels, and
tighten loose bolts. This reduces breakdowns and increases machine life.

2. Planned Maintenance:
Planned Maintenance focuses on scheduling maintenance activities to prevent unexpected
machine failures.
Steps:
 Equipment Condition Assessment:
The current condition of machines is checked to identify wear, damage, or potential
failure.
 Maintenance Planning and Scheduling:
Maintenance activities are planned in advance to avoid production interruptions.
 Preventive Maintenance:
Regular maintenance is performed to prevent breakdowns before they occur.
 Predictive Maintenance:
Machine data and condition monitoring are used to predict failures in advance.
 Breakdown Analysis:
Causes of machine failures are analyzed to prevent repeat problems.
 Maintenance Performance Review:
Maintenance results are reviewed to improve future planning and efficiency.
Tools:
 Maintenance Schedule Charts:
Show planned maintenance activities and their timing clearly.
 CMMS (Computerized Maintenance Management System):
Software used to manage maintenance schedules, records, and work orders.
 Preventive Maintenance Checklists:
Help ensure all routine maintenance tasks are completed properly.
 Failure History Records:
Keep track of past breakdowns to identify recurring problems.
Example:
A factory schedules monthly inspections for machines instead of waiting for breakdowns, which
reduces downtime and repair costs.

3. Quality Maintenance:
Quality Maintenance ensures machines consistently produce defect-free products.
Steps:
 Identify Quality Defects:
Product defects are identified during production or inspection.
 Analyze Root Causes:
The main causes of defects are analyzed to avoid repetition.
 Set Quality Standards:
Clear quality standards are defined for machines and processes.
 Maintain Optimal Machine Conditions:
Machines are kept in proper condition to meet quality requirements.
  Monitor Quality Continuously:
Quality is checked regularly to detect problems early.
Tools:
 Quality Control Charts:
Used to monitor product quality and process variation.
 Root Cause Analysis:
Helps find the real reason behind quality defects.
 Poka-Yoke (Mistake-Proofing):
Devices or methods that prevent errors during operation.
 Standard Operating Procedures (SOPs):
Written instructions to ensure consistent and correct work practices.
Example:
A bottling company installs sensors to detect incorrect bottle filling, preventing defective
products from reaching customers.

4. Focused Improvement (Kobetsu Kaizen):

Focused Improvement aims to eliminate losses and improve productivity through small,
continuous improvements.
Steps:
 Identify Major Losses:
Key losses such as downtime, defects, or delays are identified.
 Form Improvement Teams:
Small teams are created to work on specific improvement problems.
 Analyze Problems:
Problems are studied to understand their root causes.
 Implement Improvement Actions:
Practical solutions are applied to reduce or eliminate losses.
 Measure Results:
Performance is measured to check the effectiveness of improvements.
 Standardize Improvements:
Successful improvements are made part of standard procedures.
Tools:
 Kaizen:
A continuous improvement approach focusing on small, daily improvements.
 Pareto Analysis:
Helps identify the most important problems causing major losses.
 Fishbone Diagram:
Used to analyze possible causes of a problem.
 OEE (Overall Equipment Effectiveness):
Measures machine performance, availability, and quality.
Example:
A production team reduces machine setup time by rearranging tools, increasing production
output.

5. Early Equipment Management:

Early Equipment Management ensures new machines are designed and installed for easy
operation and maintenance.
Steps:
 Equipment Design Review:
Machine designs are reviewed to ensure efficiency and ease of use.
 Maintenance-Friendly Design:
Equipment is designed so maintenance tasks can be done easily and safely.
 Risk Assessment:
Possible risks and failures are identified before installation.
 Trial Runs:
Machines are tested to confirm proper performance before full operation.
 Standardization:
Best practices and machine settings are standardized.
 Knowledge Transfer:
Information is shared with operators and maintenance staff for proper usage.
Tools:
 FMEA (Failure Mode and Effects Analysis):
Identifies potential failure modes and their impact on equipment.
 Design Checklists:
Ensure all design and maintenance requirements are met.
 Lessons-Learned Database:
Stores past experiences to avoid repeating mistakes.
Example:
Before installing a new machine, engineers include easy-access panels to simplify maintenance
work.

6. Training and Education:

Training and Education improve employee skills and knowledge to support TPM activities.
Steps:
 Skill Gap Analysis:
Current skills are compared with required skills to identify gaps.
 Training Plan Development:
A structured training plan is prepared based on skill needs.
 Technical Training:
Employees are trained on machine operation and maintenance.
  TPM Awareness Programs:
Programs are conducted to explain TPM concepts and benefits.
 Skill Certification:
Employees are certified after successfully completing training.
 Continuous Learning:
Ongoing learning is encouraged to improve skills regularly.
Tools:
 Skill Matrix:
Shows employee skill levels and training requirements.
 Training Manuals:
Provide written instructions and guidelines for training.
 Workshops:
Interactive sessions to enhance practical knowledge.
 On-the-Job Training:
Employees learn by performing tasks under supervision.
Example:
Operators receive training on machine troubleshooting, reducing dependence on maintenance
staff.

7. Safety, Health & Environment (SHE):

This pillar ensures a safe, healthy, and environmentally friendly workplace.
Steps:
 Hazard Identification:
Potential safety and environmental hazards are identified at the workplace.
 Risk Assessment:
Risks are evaluated to determine their severity and impact.
 Safety Standards Development:
Safety rules and procedures are developed to control risks.
 Safety Training:
Employees are trained on safe working practices and procedures.
 Emergency Preparedness:
Emergency plans are prepared for accidents or natural disasters.
 Continuous Monitoring:
Safety performance is monitored regularly to prevent incidents.
Tools:
 Safety Audits:
Regular inspections to ensure safety rules are followed.
 PPE (Personal Protective Equipment):
Equipment like helmets, gloves, and masks used for protection.
 Risk Assessment Forms:
 Documents used to record hazards and control measures.
 Safety Signage:
Signs and symbols that warn and guide employees for safety.
Example:
A factory provides safety gloves and conducts regular safety drills to prevent workplace
accidents.

8. TPM in Office
TPM in Office applies TPM principles to administrative and office functions.
Steps:
 Identify Office Process Losses:
Delays, errors, and unnecessary activities in office work are identified.
 Streamline Workflows:
Office processes are simplified to improve efficiency.
 Improve Communication:
Clear and fast communication is encouraged between departments.
 Reduce Paperwork:
Unnecessary documents are reduced to save time and cost.
 Use Digital Systems:
Software and digital tools are used to improve accuracy and speed.
 Monitor Performance:
Office performance is reviewed regularly for continuous improvement.
Tools:
 Process Flow Charts:
Visually show office processes to identify inefficiencies.
 5S for Office:
Organizes office space for better productivity and cleanliness.
 ERP Systems:
Integrate and manage office operations through a single system.
 Kaizen:
Encourages continuous improvement in office activities.
Example:
An office reduces approval delays by digitizing documents, improving efficiency and response
time.
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