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TPM GENERAL MAINTENANCE REQUIREMENTS OF THE INTERNATIONAL
STANDARD ISO 9001:2015 AND IATF 16949:2016.
N.S.Sotvoldieva
Assistant Andijan State Technical Institute.
Abstract:
Since it is based on the ISO 9001 standard, it can be easily integrated with already
established management systems, such as ISO 14001. As a result, the implementation of IATF
16949:2016 requires significantly less financial and time investment, while providing good
prospects for further business development. The organization's partners and customers are
interested in the confirmation of the quality of the manufacturer's products. Thus, the presence
of a certificate of compliance with the requirements of the IATF 16949:2016 standard leads to
consistently high product quality and demonstrates the stability of the supplier company.
Keywords:
ISO, TPM. Certificate, standard, defect, supply, leadership, demand, improvement,
version.
The International Organization for Standardization (ISO) is an international organization for
standardization founded on February 23, 1947. The headquarters of this organization are
located in Geneva, Switzerland. The goal of the ISO international organization is to improve the
quality of products and services worldwide by developing and implementing international
standards. The ISO organization currently has more than 169 member countries. Uzbekistan is
among these countries. In 2000, the ISO organization released the ISO 9001:2000 version. This
version introduced a process-based approach. In 2008, ISO 9001:2008 was released. This
standard provides for further clarification and improvement of existing systems. By 2015, the
world's most famous international version, ISO 9001:2015, was produced. This version focuses
more on the needs of organizations and stakeholders based on risks. The ISO 9001:2015
standard consists of 10 sections , the main requirements of which are as follows.[
2
]
Leadership is the responsibility of top management, quality policy.
Planning, risk and opportunity analysis, quality objectives.
Support resources, skills, products and services.
Results assessment, monitoring, measurement, internal audits, management review.
Improvement, bug fixes, continuous development.
ISO 9001 is the most widely used quality management system standard worldwide. As of 2024,
it is used in more than 169 countries. More than a few hundred thousand certificates are issued
each year. In 2023, more than 1 million companies worldwide were ISO 9001 certified. IATF
16949:2016 is an international automotive industry standard and technical certification. The
standard specifies requirements for quality management systems for companies involved in the
design and maintenance of products in the automotive industry . IATF 16949:2016 and ISO
9001:2015 provide industry-wide requirements for the management and monitoring of safety-
related components for products with integrated software.[
2
]
The version of IATF 16949:2016 was developed after the revision of ISO 9001:2008 in 2009.
ISO 9001:2008 has specific requirements for the application in the automotive industry and
related parts manufacturing organizations. The purpose of IATF 16949:2016 is to specify the
requirements for an organization's quality management system . (Figure 2.1.1)
Scheme 2.1.1
IATF 16949:2016 quality management system requirements
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IATF 16949:2016 is a standard developed by the International Automotive Working Group
IATF and Japanese automobile manufacturers. IATF 16949:2016 is a standard developed by
Technical Committee 176 and is based on the structure of ISO 9001:2008 . Scope of
certification The IATF 16949:2016 standard applies to all organizations in the automotive
equipment and component supply chain. The specific feature of the IATF 16949:2061
application specifies requirements for organizations to use a number of tools. Manufacturers of
automotive parts or suppliers of services such as storage, transportation, calibration, etc. cannot
be certified in accordance with the requirements of IATF 16949:2016 in their quality
management system. The requirements of the sections of the standard are the same as those of
ISO 9001:2008. (Section 2.14) Defect reduction is based on the implementation of the process
for implementing this clause. The enterprise has the opportunity to improve the efficiency of
production processes and, as a result, reduce the number of defective products, resources and
time costs. Defect reduction is based on the implementation of the process for implementing
this clause. Thanks to its use, the enterprise has the opportunity to increase the efficiency of
production processes and, as a result, reduce the number of defective products, resource and
time costs.
Scheme 2.1.4
Reduce defects is based on the implementation of the process of implementing this item.
Thanks to its use, it is possible to increase the efficiency of the enterprise's production
processes and, as a result, reduce the number of defective products, resource and time costs.
Certification has become a mandatory condition for trade relations for almost all automotive
companies. The reason is that it makes it much easier to do business in this system, it is a
standard recognized all over the world.
Obtaining a certificate of conformity to IATF 16949:2016 helps to solve problems with FMEA ,
SPC , MSA and PPAP indicators. (Table 2.2) Auditing is voluntary. All major global
automobile manufacturers require their automotive component suppliers to conduct it. This also
applies to second-tier and subsequent suppliers. Statistics on certification of quality
Doimiy takomillashtirish;
Nuqsonlarning oldini olish;
Ta'minot zanjiridagi oʻzgarishlar va
yoʻqotishlarni kamaytirishi.
ISO 9001:2008
Boshqaruv mas’uliyati
Resurslarni
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management systems according to IATF 16949:2016. By the end of December 2011, 47,512
IATF 16949:2016 certificates had been issued in 86 countries. The countries with the largest
number of certificates are: China, the Republic of Korea, the USA, and in Europe, Germany is
the leader. The requirements of clause 8.5.1.5 of the international standard IATF 16949: 2016
for reducing downtime and improving efficiency are widely used. (Table 2.1.1)
Table 2.1.1
Key indicators
of IATF 16949:2016 .
PPAP
Production Part Approval Process - Component Production Approval
Process
Failure mode and impact analysis is an analysis of the types and
consequences of possible failures.
SPC
Statistical process control
MSA
Measurement System Analyses.
The maintenance and repair system plays an important role in ensuring the production
efficiency of an enterprise. The condition of equipment, technological lines and production
facilities directly affects product quality, production continuity and labor productivity. In this
section, we will consider the current state of the maintenance and repair system at the enterprise,
existing problems and opportunities for improvement . General description of the existing
system In most enterprises, the maintenance and repair process is carried out in planned and
emergency ways.
Scheduled preventive maintenance includes scheduled inspections and maintenance work based
on equipment life, production load, and production schedules. Emergency maintenance is the
rapid repair work performed when unexpected equipment failures occur.
Production line downtime, production schedule disruption, quality degradation, and increased
repair costs are possible. Currently, a separate engineering and technical service department has
been established for maintenance work, and the following groups operate within this
department. (Scheme 2.2.1) Although there is a clear maintenance schedule, it is not always
fully followed. In some cases, maintenance is delayed, carried out after a malfunction is
detected in the equipment. This helps to strengthen the positive approach instead of prevention.
Condition of equipment and level of maintenance Most of the equipment used in the enterprise
has a service life of 5–8 years.
Scheme 2.2.1
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Master groups at the enterprise
Condition of equipment and level of maintenance Most of the equipment used in the enterprise
has a service life of 5–8 years. Although some of it is modern, most of it is outdated and often
breaks down. The low rate of equipment renewal and failure to replace outdated technologies
increase the maintenance load. Factors that lead to a decrease in the quality of maintenance;
Lack of sufficiently modern diagnostic tools;
Lack of staff training courses;
Poor supply of spare parts for repairs;
Lack of electronic monitoring systems;
The company's technical maintenance system is not yet fully developed.
Maintenance is carried out as planned. Modern approaches to maintenance TPM, CMMS
Computerized Maintenance Management System are not sufficiently implemented. Lack of
qualified personnel, training of maintenance personnel is not constantly updated. The number of
maintenance (MTO) indicators is calculated by year or month. (Table 2.2.1)
Technical service indicators
Table 2.2.1
No.
Technical service
1
Number of failures
2
Equipment life span
3
Reliability level (%)
4
Number of production downtimes
5
Number of employees allocated to maintenance and repair
6
Repair costs
Zaxira ta’minot guruxilari
Mexanik ustalar guruxi
Elektr mutaxassislari guruxi
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7
Number of repairs
The TXQT system will be gradually improved based on TPM (Total Productive Maintenance);
－
Implementation of diagnostic and monitoring systems;
－
It is necessary to reduce technical failures by purchasing new equipment and modern
equipment. Maintenance and repair work at the enterprise is carried out in an emergency
approach. Information on the maintenance of the main equipment and technological systems.
(Table 2.2.2)
Table 2.2.2
Toyota maintenance services per year;
No. Year
Number
of TCCs
Number
of repairs
Number
of
failures
Reliability (%)
Costs
(million $)
1
2021
120
15
30
85%
30
2
2022
135
40
28
80%
36
3
2023
140
42
21
84%
41
4
2024
155
47
20
86%
49
Maintenance processes are regularly monitored and the quality of each service is assessed.
Special systems are used to analyze the efficiency and quality of services. Cost reduction and
efficiency improvement include the development of processes for optimizing short-term
services and repair processes. A fast and efficient maintenance system creates greater
convenience for customers and reduces enterprise costs. By creating special packages for
services and offering them to customers, it is possible to increase the profit of the enterprise.
The timely delivery of spare parts and materials during maintenance affects the fast and
efficient performance of the service. A system for storing spare parts in optimal quantities and
their effective use increases the efficiency of the enterprise. This includes factors such as the
introduction of modern technologies, improving staff skills, and improving customer relations.
With the help of such measures, the maintenance system becomes more efficient and helps to
increase the overall efficiency of the company.
To determine the level of uninterrupted operation of equipment, we work with the indicators of
mean time between failures (MTBF) and mean time to repair (MTTR). (Table 2.2.3)
MTBF
– how many hours of average operation does it take for a device to fail?
MTTR
is the mean time to repair after a failure, in hours.
This indicates that the reliability of the enterprise's equipment is relatively stable. For some
obsolete equipment, the MTBF indicator is lower, which negatively affects the continuity of
production.
Table 2.2.3
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No.
MTBF - MTTR indicators goals
1
Optimization of production based on TPM principles
2
Quickly upgrade outdated equipment
3
Modern digitalization of technical service and diagnostics systems
4
Regular training and development of employees in a culture of quality and reliability.
The introduction of TPM is a general production-wide effective maintenance system, the
purpose of which is to keep equipment in working order, eliminate malfunctions and unplanned
downtime. Equipment maintenance is the responsibility not only of technical personnel, but
also of direct operators. Each employee “looks after” his equipment and takes care of it. For
example, in some organizations operating in the Tashkent automotive industry, it is
recommended to first implement the 5S discipline to organize the workplace, get rid of excess
items and materials, maintain cleanliness, and standardize standards. At the next stage,
operators are trained in simple maintenance, autonomous service, and minor malfunctions are
quickly eliminated by the workers themselves. In international experience, for example, a large
company Toyota is trying to achieve a “zero failure” regime by analyzing equipment
malfunctions using the TPM system. Enterprises can achieve high results by developing
maintenance schedules, implementing autonomous service practices, and implementing the
necessary diagnostic tools.
REFERENCES USED:
1. "Improving production systems in the automotive industry" — textbooks and articles
published in various higher educational institutions of Uzbekistan.
2. "GM Uzbekistan: Improving Production and Technologies" - internal methodological
manuals of GM Uzbekistan.
3. "Effective production management based on TPM" — articles published in scientific journals
of Uzbekistan.
4. Nakajima, Seiichi. "Total Productive Maintenance: A Key to Improved Productivity" — a
book about how to implement TPM methodology in production processes.
5. Hirano, Hiroyuki. "Lean Manufacturing and TPM: A Japanese Approach to Productivity" —
teaches how to apply TPM in Japan.
6. "Journal of Manufacturing Science and Engineering" — a scientific article on TPM and
manufacturing improvement.
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5. " Improvement of automotive industry based on TPM, bibliographic analysis " Articles
published in the journals Innovation in the modern education system.[
1
]
6. Introduction of total technical maintenance (TRM -total productive maintenance) / AA
Mamajonov, OO Abdujabborov. –Tashkent. Scientific and technical journal "Milliy standart".
2023. No. 1. 19-22b
