Focus Areas

• Definition, goals and benefits ( Tangible and Intangible ) of TPM
• History of TPM
• TPM Metrics and how to measure them
• Understand the Pillars of TPM
• Systematic thinking for Problem solving
• Loss Cost Matrix
• OEE – Overall Equipment Effectiveness
• Some of the key TPM pillars, activities in more detail –
  • 5S, 3S and 3D workshops
  • Basic Safety, Job Safety Analysis
  • Focused improvement
  • Preventive Maintenance
  • Manager Model Machine
  • Autonomous Maintenance
  • Quality Maintenance
• Management of TPM – Roles of Senior Leadership to Front line operation teams for transformation
• Implementation steps, 12 steps Master plan
• Financial benefits
• A Company case study of TPM implementation

Background

‘Total Productive Maintenance’ (TPM) is a methodology to maximize equipment effectiveness and manufacturing processes through the involvement of all the people in the organization. TPM deals with all Operational aspects of a company through Asset care, hence the name "Total."
TPM is the fundamental requirements to achieve manufacturing excellence that will ensure significant improvement in Productivity, Quality, Cost, Delivery, Safety and Employee Morale. TPM visibly transforms the workplace and raises the knowledge and skill of Production and Maintenance teams.
It was pioneered by JIPM (Japan Institute of Plant Maintenance) and it became rapidly popular across manufacturing world as provides dramatic improvement. The tangible results of implementing TPM are reduced unplanned downtime, increased life of equipment and its performance, reduced defects and accidents, reduced inventory, trims labour and capital costs and total employee involvement in improving plant performance.
TPM strives to achieve Zero Losses by achieving Zero Breakdown and interruption, Zero Defect and Zero Accident. Effective implementation of 8 Pillars of TPM contribute toward realizing the goals in this journey.
It will lead to significant improvement of customer satisfaction and big savings of cost and time. It is all the more imperative today when we are striving toward Atmanirbhar (Self-reliant) India and Government of India is prioritizing ‘Make in India’ for both local consumptions and global supplies. Manufacturing excellence through TPM is the key contributor to achieve that vision and become globally competitive.
Keeping this in view, Indian Machine Tool Manufacturers' Association (IMTMA) is organizing an online training on “TPM – The foundation for Manufacturing Excellence”.

Key Takeaways

• Understand and appreciate the objectives of TPM
• Learn how 8 Pillars contribute in Mfg. excellence
• Learn to develop an effective TPM program in the organization
• Learn practices and steps to implement some of the important TPM pillars
• Use the training materials and various examples as reference for implementation.

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