508111 B: Total Productive Maintenance in Printing
Teaching Scheme: Examination Scheme:
Lectures: 3 Hrs. / Week Credits: 3
Theory: 100 Marks
1. Introduction – Defining TPM, Need & Objectives, Benefits, Stages of implementing TPM in
Printing, Tools in TPM – 5 Why, 4M, 5W1H, QA, QX & QM Matrix, One-Point Lesson, Equipment
Maintenance – Mechanical Systems Maintenance, Pneumatic Systems Maintenance, Electrical &
Electronic Parts- Maintenance.
2. Autonomous Maintenance – Mission, Target, 5S, Routes of Autonomous Maintenance such as initial
cleaning, eliminating sources of dirt, inspection & lubrication standards, General inspection,
Autonomous inspection, Standardization & Autonomous Management.
3. Focus Improvement – Mission, Target, Effect of Focus Improvement, Overall Equipment Efficiency,
Histogram, Pareto Analysis, Brainstorming, Data Collection, Routes of FI to overcome Losses such
as Process Waste, Set-Up Waste, Productivity Waste, Short-Stop & Speed Loss.
4. Planned Maintenance – Mission, Target, Routes for Planned Maintenance such as Understanding &
Restoring Basic conditions, Maintenance Informative System, Periodical Maintenance, Predictive
Maintenance such as Lubricant analysis, Vibration Analysis, Web Break, Noise monitoring,
Evaluation of Planned Maintenance, Breakdown Reduction & Analysis for Pre-Press, Press & Post-
Press, Mean down Time Reduction, Methods to increase Life-span of spare parts.
5. Quality Maintenance – Mission, Target, Press Optimization & Standardization, Methods for Defect
Reduction, Over usage Reduction, Statistical Process Control, Control Charts for subgroups,
individual, Run Chart, Runs Test, Quality Tools such as Cause & Effect Diagram, Capability
6. Supporting Pillars – Mission, Target & Routes of Training & Education, Office TPM, Safety, Health
& Environment, Cost, Logistics, Early Equipment Management.
1. Kenneth E. Rizzo, Total Production Maintenance-A Guide for the Printing Industry, 2nd Edition,
GATF Press, July 2001.
2. Nakajima S, Introduction to Total Production Maintenance Productivity Press, 1984.
3. P. Kandasamy, K. Thilagavathi, K. Gunavanthi, Probability Statistics and Queueing Theory, S.
Chand Publication, Edition I, 2004.
4. R. C. Mishra & Pathak K, Maintenance Engineering & Management, Prentice Hall of India
5. J. Juran, Handbook of Quality Control, Tata Mc Graw Hill Publication, 5th Edition, 1951.
6. N. K. Mehta, Machine Tool & Numerical Control, Tata Mc Graw Hill Publication, 1996.
7. S. R. Mujumdar, Pneumatic Systems: Principles & Maintenance
8. J. K. Sharma, Operation Research-Theory and Application, MacMillan India Ltd., New Delhi
9. Col. D. S. Cheema, Operation Research, Laxmi Publications (P) Ltd., Bangalore.
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