Office TPM

use trained maintenance staff to help train the operators to better maintain their equipment.

Policy

1. Achieve and sustain availability of machines;

2. Optimum maintenance cost;

3. Reduces spares inventory; and

4. Improve reliability and maintainability of machines.

Target

1. Zero equipment failure and breakdown;

2. Improve reliability and maintainability by 50%;

3. Reduce maintenance cost by 20%; and

4. Ensure availability of spares all the time.

Six Steps in Planned Maintenance

1. Equipment evaluation and recoding present status;

2. Restore deterioration and improve weakness;

3. Building up information management system;

4. Prepare time based information system, select equipment, parts and members and map

out plan;

5. Prepare predictive maintenance system by introducing equipment diagnostic techniques;

and

6. Evaluation of planned maintenance.

PILLAR 5—QUALITY MAINTENANCE

It is aimed towards customer delight through highest quality through defect free manufacturing.

Focus is on eliminating non-conformances in a systematic manner, much like Focused Improvement.

We gain understanding of what parts of the equipment affect product quality and begin to

eliminate current quality concerns, then move to potential quality concerns. Transition is from

reactive to proactive (Quality Control to Quality Assurance).

QM activities is to set equipment conditions that preclude quality defects, based on the basic

concept of maintaining perfect equipment to maintain perfect quality of products. The conditions

are checked and measure in time series to very that measure values are within standard values

to prevent defects. The transition of measured values is watched to predict possibilities of defects

occurring and to take counter measures before hand.

Policy

1. Defect free conditions and control of equipments

use trained maintenance staff to help train the operators to better maintain their equipment.

Policy

1. Achieve and sustain availability of machines;

2. Optimum maintenance cost;

3. Reduces spares inventory; and

4. Improve reliability and maintainability of machines.

Target

1. Zero equipment failure and breakdown;

2. Improve reliability and maintainability by 50%;

3. Reduce maintenance cost by 20%; and

4. Ensure availability of spares all the time.

Six Steps in Planned Maintenance

1. Equipment evaluation and recoding present status;

2. Restore deterioration and improve weakness;

3. Building up information management system;

4. Prepare time based information system, select equipment, parts and members and map

out plan;

5. Prepare predictive maintenance system by introducing equipment diagnostic techniques;

and

6. Evaluation of planned maintenance.

PILLAR 5—QUALITY MAINTENANCE

It is aimed towards customer delight through highest quality through defect free manufacturing.

Focus is on eliminating non-conformances in a systematic manner, much like Focused Improvement.

We gain understanding of what parts of the equipment affect product quality and begin to

eliminate current quality concerns, then move to potential quality concerns. Transition is from

reactive to proactive (Quality Control to Quality Assurance).

QM activities is to set equipment conditions that preclude quality defects, based on the basic

concept of maintaining perfect equipment to maintain perfect quality of products. The conditions

are checked and measure in time series to very that measure values are within standard values

to prevent defects. The transition of measured values is watched to predict possibilities of defects

occurring and to take counter measures before hand.

Policy

1. Defect free conditions and control of equipments

Phase 1: Do not know.

Phase 2: Know the theory but cannot do.

Phase 3: Can do but cannot teach.

Phase 4: Can do and also teach.

Policy

1. Focus on improvement of knowledge, skills and techniques;

2. Creating a training environment for self-learning based on felt needs;

3. Training curriculum/tools/assessment etc. conducive to employee revitalization; and

4. Training to remove employee fatigue and make work enjoyable.

Target

1. Achieve and sustain downtime due to want men at zero on critical machines;

2. Achieve and sustain zero losses due to lack of knowledge/skills/techniques; and

3. Aim for 100% participation in suggestion scheme.

Steps in Educating and Training Activities

1. Setting policies and priorities and checking present status of education and training;

2. Establish of training system for operation and maintenance skill upgradation;

3. Training the employees for upgrading the operation and maintenance skills;

4. Preparation of training calendar;

5. Kick-off of the system for training; and

6. Evaluation of activities and study of future approach.

PILLAR 7—OFFICE TPM

Office TPM should be started after activating four other pillars of TPM (JH, KK, QM,

PM). Office TPM must be followed to improve productivity, efficiency in the administrative

functions and identify and eliminate losses. This includes analyzing processes and procedures

towards increased office automation. Office TPM addresses twelve major losses. They are:

1. Processing loss;

2. Cost loss including in areas such as, procurement, accounts, marketing, sales leading to

high inventories;

3. Communication loss;

4. Idle loss;

5. Set-up loss;

6. Accuracy loss;

7. Office equipment breakdown;

8. Communication channel breakdown, telephone and fax lines;

9. Time spent on retrieval of information;

10. Non availability of correct on-line stock