Introduction to TPM

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                                                   TPM -

                             Total Productive Maintenance

                                           1. INTRODUCTION TO TPM



Types of Maintenance


1. Breakdown Maintenance -

2. Preventive Maintenance -

3. Corrective Maintenance -

4. Maintenance Prevention -

5. Productive Maintenance -

6. Total Productive Maintenance



1. Breakdown Maintenance - BM


Until 1950, all companies used to just breakdown maintenance. It has the disadvantage that even if the machine does not want to be shut down, the machine has more damage, the problems of the spare parts availability, the waste of time waiting in the waiting, there is trouble finding the fault. 

1950 तक सभी कंपनियां सिर्फ breakdown maintenance करती थी। इसने यह नुकसान है कि ना चाहते हुए भी मशीन बंद करना पड़ता है, मशीन को ज्यादा नुकसान होता है, स्पेयर पार्ट्स अवेलेबिलिटी की समस्या, इंतजार में समय की बर्बादी, खराबी खोजने में परेशानी होती है।

2. Preventive Maintenance - PM

This system started in 1951. Instead of waiting for a breakdown in this method, the position of the machine is checked periodically and it is cured if needed

इस system का आरंभ 1951 में हुआ। इस पद्धति में ब्रेकडाउन होने का इंतजार करने के बजाय समय-समय पर मशीन की स्थिति की जांच  की जाती है तथा जरूरत पड़ने पर उसको ठीक किया जाता है।

3. Corrective Maintenance - CM


This system started in 1957. In addition to preventive maintenance, more attention was paid to prevent the machine from spoiling so that the efficiency of the machines would be improved and maintenance of machines would be easier.

इस system का प्रारंभ 1957 में हुआ था । जिसमें preventive maintenance को और आगे बताते हुए machine को खराब होने से बचाने के लिए अधिक ध्यान दिया जाने लगा ताकि मशीनों की विश्वसनीयता बढे साथ ही मशीनों  का मेंटेनेंस आसान हो जाए


4. Maintenance Prevention - MP


This steam started in 1960. This system The design of the machine is made so that it becomes free from the hassle of maintenance. Such an ideal situation is created - machine and line are brought to such ideal condition 

इस स्टीम का आरंभ 1960 में हुआ । इस system में मशीन का डिजाइन ही ऐसा बनाया होता है कि वह maintenance की झंझट से मुक्त हो जाते हैं। ऐसे एक आदर्श स्थिति बनाई जाती है - मशीन और लाइन को ऐसी आदर्श स्थिति में लाया जाता है

5. Productive Maintenance - PM

In this system, such measures are taken to increase the productivity of the machine, it is called productive maintenance. 
इस system में मशीन की प्रोडक्टिविटी बढ़े, ऐसे उपाय किए जाते हैं - उसे productive maintenance कहते हैं


6. Total Productive Maintenance - TPM

This is a Japanese system. In which TPM is done by all the employees in small groups. This system was used by Nippon Denso Company Limited

यह एक जापानी सिस्टम है । जिसमें  TPM छोटे-छोटे ग्रुप में सभी कर्मचारियों द्वारा किया जाता है । इस सिस्टम को निप्पॉन डेंसो कंपनी लिमिटेड द्वारा काम में लाया गया था


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What is TPM ?

Total (संपूर्ण)  - सभी लेवल के कर्मचारियों द्वारा, सभी कामों में
Productive ( उत्पादकता ) -  effective utilisation of man machine tools and energy
Maintenance - Keep man, machine, tools and system in good condition ( man machine tools and system को सबसे अच्छी स्थिति में रखन)

What is the goal of TPM ?

- To achieve zero losses
- to improve productivity
- make Genna - Genbetsu ( go and see) system
- Top to bottom all members involvement


Benefits of TPM

- zero breakdown
- zero defects
- zero accidents and zero pollution
- reduction in cost
- increase the overall equipment effectiveness - OEE
- increase in company profit
- Improve work culture ( shiny, good housekeeping, कर्मचारियों की सोच में बदलाव)


The eight pillars of TPM

  1. Autonomous Maintenance
  2. Focused Improvement
  3. Planned Maintenance
  4. Quality management
  5. Early/equipment management
  6. Education and Training
  7. Safety Health Environment
  8. Administrative & office TPM




5S system is the base of TPM system

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