TPM

(Maintenance and Management)

TOTAL PRODUCTIVE MANAGEMENT

TPM PROMOTOR PTSG

TPM :
TOTAL PRODUCTIVE MAINTENANC E

TQM :
TOTAL QUALITY 5R MANAGEMENT

JIT :
JUST IN TIME

5P/5S
Budaya Perusahaan
TPM PROMOTOR PTSG

TPM Basic Policy

PT Semen Padang menyadari bahwa kelancaran operasional merupakan sumber dari kemajuan perusahaan, oleh karena itu pengoperasian dan pemeliharaan asset perusahaan harus di optimalkan. Untuk mencapai tujuan tersebut PT.Semen Padang menerapkan Total Productive Maintenance (TPM) pada seluruh aktivitas perusahaan, agar tercipta budaya kerja yang lebih produktif dan efisien. Penerapan TPM melibatkan semua jajaran struktural
/fungsional pada seluruh level dalam perusahaan.
TPM PROMOTOR PTSG

TPM Goal ?
Profit
Profit

16 Major Losses

INCREASE PROFIT REDUCE COST

Profit

Non Value Adding

Cost

Non Value Adding

Value Adding Material + Energy

Minimal
Optimum Optimum

Value Adding Material + Energy

TPM PROMOTOR PTSG

8 Activities and Loss

Partial Improvement Safety, Hygiene, Environment

Autonomous Maintenance

Office TPM

Loss

Planned Maintenance

Quality Maintenance Development Management

TPM PROMOTOR PTSG

Education & Training

TPM PROMOTOR PTSG

Autonomous Maintenance (AM)

Management Index
1. Increase Production.
Increase Productivity 2. Production Manpower x Man hour 3. 4. 5. 1.

Activity Result Index

Time reduction of cleaning, inspection, retightening, lubrication. Breakdown reduction due to poor AM Defect reduction due to poor AM. Downtime Reduction Reduction, Elimination of quantity Parts and material, which drop during processing Total Saved Money by preventing leakage of oil material 1. 2. 3. 4. 5. 6. 7.

Activity Index (Example)

Number of Tags attached and removed Number of One Point Lesson sheets. Number of Good to find cases. Number of repair by operators Score of 5S activity. Number of repaired malfunctions by operator. Education Time by using One Point Lesson Sheets. Trends of AM Step Number of visual control Number of suggestion

2. 3. 4.

Decrease Cost Customer Complaint reduction Zero Accident

6.

TPM PROMOTOR PTSG

8. 9. 10.

Partial Improvement (PI)

Management Index
1. Increase Production.
Increase Productivity Production Manpower x Man-hour

Activity Result Index

1. 2. 3. 4. 5. 6. Overall Equipment Efficiency. Overall Line Efficiency Overall Plant Efficiency WIP Total Down Time Total Saved Money 1.

Activity Index (Example)

Number of PI by ;
Project team Circle member Engineering staff

2. 3. 4. 5.

2. 3. 4.

Decrease Cost Customer Complaint reduction Zero Accident

Number of PI for 16 Loss. Number of PI for each loss Number of Horizontal deployments. Number of Cases in which various methods are used.

TPM PROMOTOR PTSG

Planned Maintenance (PM)

Management Index
1. Increase Production.
Increase Productivity 2. Production Manpower x Man-hour 3. 4. 5. 6. 1.

Activity Result Index

Reduction of downtime due to Breakdown Improvement of MTBF, MTTR Reduction Spare Parts. Reduction of Oil Consumption, Electricity. Reduction of Downtime. Reduction of repair cost (manpower, subcontractor). Number of Inspection, repairs in-house from subcontractor. 1. 2. 3. 4. 5. 6. 7. 8.

Activity Index (Example)

Preventive Maintenance implementation rate. Number of Corrective Maintenance activities. Number of MP Sheets Number of machines under CBM. Number of Breakdown re- occurrence. Skill upgraded of maintenance workers. Multi-skill maintenance workers. Number of Red-Tags removed.

2. 3.

4.

Decrease Cost Customer Complaint reduction Zero Accident

7.

TPM PROMOTOR PTSG

Quality Maintenance (QM)

Management Index
1. Increase Production.
Increase Productivity Production Manpower x Man-hour 2. 3. 1.

Activity Result Index

Reduction of quality defects. Amount of saved money. Reduction of inspection time, manpower. Reduction of Customer Complaints. 1. 2.

Activity Index (Example)

Number of small Improvement. Zero cases.
Product Item Machines Lines One month Three month Six month More than six months

4.

3.

Duration of Zero cases.

2. 3.

4.

Decrease Cost Customer Complaint reduction Zero Accident

4.

Numbers of revised standards

TPM PROMOTOR PTSG

Education & Training (T&E)

Management Index
1. Increase Production.
Increase Productivity Production Manpower x Man-hour 2. 1.

Activity Result Index

Reduction of Downtime, Breakdown due to lack of knowledge and skill. Reduction of Downtime, Breakdown after getting knowledge and skill. Reduction of quality, Defect, rework after getting knowledge and skill. Reduction of subcontractor job after getting skill. 1.

Activity Index (Example)

Total time of Education, Training for operator and Maintenance worker. Total Item of E & T Number of One-Point Lesson Sheets. Number of delegates for seminars. Evaluation of knowledge & Skill. Number of Small Improvement proposed.

2. 3. 4. 5. 6.

3.

2. 3.

4.

Decrease Cost Customer Complaint reduction Zero Accident

4.

TPM PROMOTOR PTSG

Safety, Hygiene & Environment (SHE)

Management Index
1. Increase Production.
1. Increase Productivity 2. 3. 4. 5. 6.

Activity Result Index

Reduction of accident. Reduction noise. Create excellent workshop 5S Reduction of downtime by no accident. Saving by reduced energy consumption. Reduction of Industrial waste quantity. 1. 2. 3. 4. 5.

Activity Index (Example)

Number of Improvement for unsafe place, action. Number of safety proposal. Total time of safety patrol (daily monthly). Number of Poka Yoke Kaizens. Score of 5S activity.

Production Manpower x Man-hour

2. 3.

4.

Decrease Cost Customer Complaint reduction Zero Accident

TPM PROMOTOR PTSG

Office TPM (Supporting)

TPM PROMOTOR PTSG

Office TPM (Supporting)

TPM PROMOTOR PTSG

Profit = Turnover - Cost

TPM PROMOTOR PTSG

Assets
Physical Assets (mesin, peralatan, bangunan dll) Human Assets (karyawan) Kowledge Assets ( Sistim, Prosedur & Teknologi Informasi)

TPM PROMOTOR PTSG

Budaya Kerja ?
Disiplin Rajin Jujur Hemat Kerjasama

TPM PROMOTOR PTSG

Perubahan Budaya ?
Hasil

Apa yg direncanakan dan dilakukan

Nilai-nilai, Keyakinan,

TPM PROMOTOR PTSG

TPM PROMOTOR PTSG