Total Productive Maintenance
Module-5

Definition
• Total Productive Maintenance (TPM) is an
approach to equipment maintenance that
aims to achieve a perfect production process
by increasing productivity, efficiency, and
safety.

Types of maintenance
• Preventive Maintenance.
• Condition-Based Maintenance.
• Predictive Maintenance.
• Corrective Maintenance.
• Predetermined Maintenance.

1. Preventive Maintenance.
• Preventive maintenance is aimed at catching and fixing
problems before they happen. It is most commonly
carried out in the form of regular inspections, usually
occurring multiple times per year.
• When you inspect a system or a piece of technology,
carefully check for all signs of wear, tear or imminent
breakdown. Replace damaged parts immediately. This
will prevent having to go into “crisis mode” if
something breaks unexpectedly.
• The primary benefit of preventive maintenance is that it
can eliminate unplanned shutdown time as you will
ideally catch problems before they occur.

2. Condition-Based Maintenance
• Condition-based maintenance is sometimes considered
to be a more advanced alternative to preventive
maintenance. Rather than being inspected according to
a schedule, machines and systems are carefully
observed for changes that could indicate upcoming
failure.
• With condition-based maintenance, technicians observe
the system running and identify variables that could
affect functioning, like temperature, vibration speed,
power, the presence or absence of moisture, and more.
• Another strategy within condition-based maintenance is
predictive maintenance.

3. Predictive Maintenance
• Predictive maintenance refers to a specific type of
condition-based maintenance in which systems are
constantly observed via sensor devices. These devices
are attached to components of the system and feed
constant, real-time data to software. The software then
interprets this data and warns maintenance technicians
of approaching danger.
• Predictive maintenance is generally considered to be
the most advanced and intensive type of maintenance.
This is because there is a lot of data to interpret – and
the sensor devices themselves need to be regularly
maintained and checked

4. Corrective Maintenance
• Corrective maintenance is initiated when a problem is
discovered while working on another work order. With
corrective maintenance issues are caught ‘just in time'.
• For example, during a scheduled maintenance check or
while fixing another issue, a maintenance technician
notices that a pipe in a HVAC system is not working as
it should. Corrective maintenance is then scheduled for
a future date where the problem is repaired or replaced.
• Because corrective maintenance issues are found ‘just
in time’, it reduces emergency repairs and increases
employee safety.

5. Predetermined Maintenance
• Unlike other styles, predetermined maintenance is
carried out using rules and suggestions created by the
original manufacturer, rather than the maintenance
team. These suggestions are based on experiments and
gathered data.
• The manufacturer provides statistics and guidelines,
usually when the equipment is first purchased and will
include data providing the average lifespan of both the
entire system and its various parts. The manufacturer
will suggest how often parts should be inspected,
serviced and replaced.

Steps in implementing of TPM
• Efficient utilization of men, materials & machine
• Planned maintenance
• Initial control
• Education & training
• Autonomous maintenance or self maintenance
• Quality maintenance
• TPM administration
• Safety, hygenic & environment

The overall goals of TPM are…
• Maintaining & improving equipment capacity
• Maintaining equipment for its intended life
• Using support from all areas of operations &
activities
• Encouraging input from all concerned
• Using team concept for continuous
improvements

Pillars of TPM

Pillars of TPM
1. Focused maintenance
2. Autonomous maintenance
3. Planned maintenance
4. Training & education
5. Early management
6. Quality maintenance
7. Office TPM
8. Safety, health & environment

Pillars of TPM
1. Focused Maintenance is an important part of the
management of the physical assets of a property.
Once the building services are installed.
2. Autonomous maintenance is a method in
manufacturing that gives machine operators
the responsibility for basic maintenance tasks,
rather than relying on dedicated maintenance
technicians.

3.Planned maintenance refers to any
maintenance activity that is planned,
documented, and scheduled.
• The aim of planned maintenance is to reduce
downtime by having all necessary resources on
hand, such as labour and parts, and a strategy
to use these resources.

4. Training & education
Education and Training (E&T) pillar of TPM
house is aimed at to have multi-skilled
revitalized employees to handle their intended
initiatives in a systematic manner.
In this pillar, the operators are
imparted necessary education and training
on maintenance engineering practices.

5. Early Management is the fifth pillar of
TPM and aims to implement new products and
processes with vertical ramp up and minimised
development lead time.
6. Quality Maintenance is the sixth pillar of
TPM and aims to assure zero defect
conditions.
• It does this by understanding and controlling
the process interactions between manpower,
material, machines and methods that could
enable defects to occur.

7. Office TPM is the seventh pillar and
concentrates on all areas that provide
administrative and support functions in the
organisation. The pillar applies the key TPM
principles in eliminating waste and losses from
these departments.
8. HSE (Health, Safety and Environment) is
a set of processes and procedures identifying
potential hazards to a certain environment,
developing best practices to reduce or remove
those hazards, and then training employees for
accident prevention, accident response, etc.

5S in TPM
• 5S is a workplace organization method that
uses a list of five Japanese words: seiri, seiton,
seisō, seiketsu, and shitsuke. These have been
translated as "sort", "set in order", "shine",
"standardize", and "sustain".

1. Sort
• The first step of 5S, Sort, involves going through all the
tools, furniture, materials, equipment, etc. in a work
area to determine what needs to be present and what
can be removed. Some questions to ask during this
phase include:
• What is the purpose of this item?
• When was this item last used?
• How frequently is it used?
• Who uses it?
• Does it really need to be here

2. Set in order
• During this phase, everyone should determine what arrangements
are most logical. That will require thinking through tasks, the
frequency of those tasks, the paths people take through the space,
etc.
• Which people (or workstations) use which items?
• When are items used?
• Which items are used most frequently?
• Should items be grouped by type?
• Where would it be most logical to place items?
– Would some placements be more ergonomic for workers than others?
– Would some placements cut down on unnecessary motion?
• Are more storage containers necessary to keep things organized?

3. Shine
• Everyone thinks they know what housekeeping is, but
it's one of the easiest things to overlook, especially
when work gets busy. The Shine stage of 5S focuses on
cleaning up the work area, which means sweeping,
mopping, dusting, wiping down surfaces, putting
tools and materials away, etc.
• In addition to basic cleaning, Shine also involves
performing regular maintenance on equipment and
machinery. Planning for maintenance ahead of time
means businesses can catch problems and prevent
breakdowns. That means less wasted time and no loss
of profits related to work stoppages.

4. Standardize
• Once the first three steps of 5S are completed, things
should look pretty good. All the extra stuff is gone,
everything is organized, spaces are cleaned, and
equipment is in good working order.
• The problem is, when 5S is new at a company, it's easy
to clean and get organized and then slowly let things
slide back to the way they were.
• Standardize makes 5S different from the typical
spring-cleaning project. Standardize systematizes
everything that just happened and turns one-time
efforts into habits. Standardize assigns regular tasks,
creates schedules, and posts instructions so these
activities become routines.

5. Sustain
• Once standard procedures for 5S are in place,
businesses must perform the ongoing work of
maintaining those procedures and updating them as
necessary.
• Sustain refers to the process of keeping 5S running
smoothly, but also of keeping everyone in the
organization involved.
• Managers need to participate, as do employees out on
the manufacturing floor, in the warehouse, or in the
office. Sustain is about making 5S a long-term
program, not just an event or short-term project.

Quality by Design (QbD)
• Quality by Design (QbD) is a strategic
process for development and
manufacturing. It is meant to ensure that the
intended performance of a final drug product is
as expected – both in terms of purity and
efficacy( Ability to produce intended result)
• To achieve this requires well-described
objectives, and proper risk management.

Key components of QbD
• QbD elements include the following:
1) A quality target product profile (QTPP)
that identifies the critical quality attributes
(CQAs) of the drug product
2) Product design and understanding including
identification of critical material attributes
(CMAs)
3) Process design and understanding including
identification

Role of QbD in Pharmaceutical industry
• Pharmaceutical QbD is a systematic approach to
development that begins with predefined
objectives and emphasizes product and process
understanding and control based on sound science and
quality risk management.
• In this progressively non-stop manufacturing
environment, QbD uses a data-driven approach
to deliver better understanding of manufacturing
processes, reduced likelihood of batch failures, more
efficient and effective control of change, as well as
greater return on investment, time and cost savings.

Benefits & challenges of QbD
Benefits
• “Right first time” – reduced costs and less
process downtime.
• Science-based understanding of the process
results in minimized batch failure or rework.
• Better consistency in drug quality and efficacy.
• Ensures therapeutic efficacy of generics.
• Reduced time to market for new drugs.

Benefits & challenges of QbD
Challenges
• Quality target product profile (QTPP)
• Critical quality attributes (CQAs) of a product.
• Product design and product understanding.
• Process design and understanding.
• Product and process control strategies.

Environmenal Management
System(EMS)
• A quality management system is a collection
of business processes focused on consistently
meeting customer requirements and enhancing
their satisfaction.
OR
• The collective plans, activities and events that
are provided to ensure that a product, process
or service will satisfy the given needs.

EMS under ISO 14001
• ISO 14001 is an internationally agreed
standard that sets out the requirements for an
environmental management system.
• It helps organizations to improve their
environmental performance through more
efficient use of resources and reduction of
waste, gaining a competitive advantage and the
trust of stakeholders.

EMS under ISO 14001
• ISO 14001 is the international standard that
specifies requirements for an effective
environmental management system (EMS).
• It provides a framework that an organization
can follow, rather than establishing
environmental performance requirements.

Costs & Benefits of EMS
• Improved environmental performance.
• Enhanced compliance.
• Pollution prevention.
• Resource conservation.
• New customers/markets.
• Increased efficiency/reduced costs.
• Enhanced employee morale.
• Enhanced image with public, regulators, lenders,
investors.

Thank you!