Class 3

Class 3

Total Productive Maintenance (TPM)

History –

1) Breakdown Maintenance – Old technique / Postmortem technique

2) Preventive Maintenance – Anticipate and take precaution earlier.

3) Predictive Maintenance – Replace all bulbs just as warranty expires even if they are in working conditions. Reason is Cost of failure >>>> Cost of bulb.

4) Total Productive Maintenance is a maintenance process developed for improving productivity by making process more reliable and less wasteful. (Prevent natural deterioration which is normally not taken off)

Poka-Yoke – Visual mistake proofing device, fool-proofing system

Jidoka – 1^st time right (as rework is very expensive)

6 Sigma – Measures process capability (whether process is performing within tolerance zone)

ERP – Integration of data and system across organization

SMED (Single minute exchange of die) – After 2^nd WW, bulk order stopped for manufacturing of vehicles. Requirement was making different vehicles with small orders. But for that, manufacturing was difficult as die used for manufacturing needed to be changed frequently for different types of vehicles (because of high set-up time for changing die). Hence, cost of vehicles were high (due to set up time)

SMED solved the problem, where die was exchanged in single digit minute (between 1-9 min). Idea was inner space of die will be as per vehicle and outer shape of all dies will be same for quick assembly.

Outsourcing (PL – Party Logistics)

1) 1PL – Producer of goods utilizes his own logistics

2) 2PL – Hires truck for transportation, though packing, loading and unloading will be done by producer

3) 3PL - The transporter packs, load / unload as well as transports the material

4) 4PL – Transporter manages the whole supply chain (Operates all the stakeholders of the supply chain)

5) 5PL – Uses IT to manage the supply chain (ERP, SAP)

TQM is a culture.

Quality costs in short run but pays in long run.