TPM_Training_Day1

Day 1: Introduction to TPM & 8 Pillars 04/22/2025 By : Jayantha Premasingha.

What is TPM?. Explanation TPM is a company-wide approach to equipment maintenance that emphasizes proactive and preventive maintenance to maximize the operational efficiency of equipment. It involves all employees, from top management to shop-floor workers, and focuses on empowering operators to take responsibility for routine maintenance. The ultimate goals are zero unplanned downtime, zero defects, and zero accidents. Example: In the sewing section, machines used to stop frequently due to minor issues like thread jams or loose screws. After introducing TPM, operators were trained to clean machines daily and tighten loose parts. In one month, downtime decreased by 35%, and output per hour increased by 18%..

1. Autonomous Maintenance (AM). Explanation: Operators carry out basic maintenance, like cleaning and inspections, to prevent minor failures. Example: Operators in Line 4 clean their sewing machines daily, checking feed dogs and oil levels. After implementing AM, machine jamming incidents dropped by 40%..

2. Planned Maintenance (PM). Explanation: A scheduled maintenance system based on machine usage and history to avoid breakdowns. Example: Maintenance team services overlock machines every 30 days (belt check, foot pressure, etc.). Emergency breakdowns reduced by 60% after regular PM began..

3. Quality Maintenance (QM). Explanation: Keep machines running within set parameters to prevent defects. Example: Skipped stitches were traced to a worn spring in the flatlock machine’s presser foot. After adding this check to PM, defect recurrence stopped..

4. Focused Improvement (Kaizen). Explanation: Small cross-functional teams identify and solve chronic losses. Example: Bobbin changes were slowing the line. By placing bobbin holders every 2 machines, they saved 12 minutes/shift and boosted productivity by 8%..

5. Early Equipment Management (EEM). Explanation: Operators and mechanics give input when selecting or designing new machines. Example: When buying new feed-off-arm machines, mechanics requested larger oil tanks and external oil gauges. This made checks easier and reduced service calls..

6. Training and Education. Explanation: Upskilling ensures staff can handle both routine and complex issues confidently. Example: Operators were trained on tension adjustment for different fabric types. This reduced puckering issues by 25% in 3 months. Suggested Picture: Training session in progress with operators handling swatches..

7. Safety, Health & Environment (SHE). Explanation: Safety measures prevent injuries and promote a clean, risk-free workplace. Example: Protective guards installed on all sewing machine belts and needles. Operators trained on proper machine shutdown procedures. Reported hand injuries reduced by 35%..

8. Office TPM. Explanation: TPM applied to office/admin tasks to support production efficiency. Example: The merchandising team began using fabric ETA boards. This cut machine downtime caused by fabric delays by 15%..