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EICHER ENGINES, ITARANA ROAD,
ALWAR (RAJ.)
(A unit of tafe motors & tractors ltd .Alwar)
Production
Productivity =
Cost
Simultaneously
OBJECTIVES OF TPM
• Achieve Zero Defects, Zero Breakdown and
Zero accidents in all functional areas of the
organization.
• Involve people in all levels of organization.
• Form different teams to reduce defects and
Self Maintenance
Direct Benefits Of TPM
• Increase productivity and OPE (Overall Plant
Efficiency) by 1.5 or 2 times.
• Rectify customer complaints.
• Reduce the manufacturing cost by 30%.
• Satisfy the customer’s needs by 100 %
(Delivering the right quantity at the right
time, in the required quality)
• Reduce accidents.
• Follow pollution control measures.
Indirect Benefits of TPM
• Higher confidence level among the employees.
• Keep the work place clean, neat and attractive.
• Favorable change in the attitude of the
operators.
• Achieve goals by working as team.
• Horizontal deployment of a new concept in all
areas of the organization.
• Share knowledge and experience.
• The workers get a feeling of owning the
machine
AUTONOMOUS MAINTENANCE
(JH)
• Concept of people who operate a
machine should also maintain the
machine.
• Starts with basic lubrication,
cleaning, inspection & then turns to
repairs.
Reasons Why Autonomous Maintenance is Required
No satisfactory increase in the performance
record can be seen …
Activities to keep record
on equipment
• Confirmation of degradation
working conditions
• Daily inspection
• Periodical inspection
Activities to prevent
equipment degradation
• Keep cleaning
• Inspection
• Additional
tightening
Activities to restore
Preventive Production the machine
Maintenance Maintenance TPM
conditions
Japanese
U.S style of PM
style of PM
Maintenance
Department’s
sole
responsibility • Frequent servicing
• Solution of abnormality
• Good communication
1. MINOR FLAWS
2. UNFULFILLED BASIC CONDITIONS
3. INACCESSABLE PLACES
4. CONTAMINATION SOURCES
5. QUALITY DEFECT SOURCES
6. UNNECCERY AND NON-URGENT ITEMS
7. UNSAFE PLACES
1. MINOR FLAWS :
整理
Seiri= Sort
Meaning in Japanese context:
Throw away all rubbish & unrelated
material in workplace.
Industrial definition:
To distinguish between necessary things
and unnecessary things.
Typical Seiri Activities
•Eliminate defects and breakage
•Organize the warehouse
BEFORE AFTER
整頓
Seiton = stabilize/organize
Meaning in Japanese context:
Set everything in proper place for quick
retrieval & storage.
Industrial definition:
It is a way of eliminating
search.
30 Second Rule
30 Second Rule
Fig 1: condition of tools
before Seiton
Definition:
Eliminating trash, filth, and foreign
matters for a cleaner workplace.
Cleaning as a form of inspection.
Key Points:
Broom
Dust pan
Mop
清潔
Seiketsu = Standardize
Meaning in Japanese context
Standardize the way of maintaining
cleanliness
INDUSTRIAL DEFINITION
Seiri Seiton
Keeping things organized, neat
and clean; in personal and
environmental aspects.
Seiso
Typical Seiketsu Activities
• Make quality manual
• Directional markings
•Color-coded pipes
Before After
DIRECTIONAL MARKINGS
Indication marks
Indication for
for nuts & bolts
valve controls
躾
Shitsuke = Self-discipline
Continue…
TS & 5s Instructions
• Gang way should be absolutely clear and
nothing should be laid there.
• Place the component only on the
conveyor, trolley or machine. And not on
the floor/platform.
• Don’t put anything (finish/scrap/tools etc)
on the floor.
Continue…
TS & 5s Instructions
• Don’t throw duster or gloves near
machine or inside tank or on the floor.
• Have to clean the resting face of fixture
after every piece.
• At the end of shift clean the side ways,
glide ways.
• Follow the standards designed for the
workplace.
Continue…
TS & 5s Instructions
• Keep the rejection/rework products aside,
do know the reason of rejection/rework
and mark it. Mark the component with
the marker, keep it at the specified place
at the end of shift before leaving the
workplace.
• Take care of cleanliness of the work
place.
AFFECT CHECK
QUESTIONNAIRE-4
Q1.What would you do in case of an emergency?
Q2.When should punch be cleaned & changed?
Q3.What kind of waste will you dispose off in
RED, BLUE & GREEN dustbins?
Q4.What is to be done to utilize ‘ideal time’?
Q5. What will you do if any component is
rejected?
AFFECT CHECK
QUESTIONNAIRE-4
Q6.How will you check oil & coolant level?
Q7.Where to use (a) ear plugs (b) safety goggles
(c) gloves?
Q8.How to check tool condition?
Q9.How will you check drill/tap sizes?