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1. Technical advancement has made the world today a border-less society. Along with that competition has also intensified. Today’s competition is ruthless and survival depends upon not only on continuous improvement and invention of new products but also on their availability at low cost, timely delivery, courteous sales and prompt after sales service.

2. Industries use many precision instruments and devices which help in monitoring and controlling raw material quality and consistency, functional efficiency of equipment and their accuracy, auto operational systems to minimize and/or to avoid variations in the methods used and POKA YOKE /Mistake proofing system to eliminate human errors.

3. Even though they all help, upkeep of equipment has become an additional responsibility. Care for equipment and allied systems have become a great need. Total Productive Maintenance (TPM) precisely meets this need.

4. By adopting TPM we can make even old machinery and systems to function trouble free. Zero failure, zero defect, zero accident and zero pollution are need of the hour and TPM helps in achieving this.

5. TPM is to maximize equipment effectiveness by establishing a thorough system of ‘Productive Maintenance’ (PM) for the entire life span of the equipment. It is implemented by various departments like engineering; production, maintenance etc., and involves everyone in the organisation. It is based on the idea of promotion of PM through autonomous small group activities.

6. TPM has now within its fold, to Zero breakdown to Zero defect to Zero accident and to Zero pollution as its goals.

7. TPM has been found to be benefiting all areas i.e. in production, quality, cost, delivery, safety and morale. In case of labour productivity, value added per person and rate of operation etc., increases and breakdown become nil or considerably less. As far as quality is concerned defects in process material as well as in processed material reduce and so also claims from customers. There will be reduction in manpower cost, maintenance cost and also results in energy conservation. As far as delivery is concerned, it leads to reduced stock and increased inventory turn over.

Roadmap recommended and used by QCFI for this.

Stage A: Preliminary or preparation stage to Top Management programmes

i) Senior Executives awareness programme.

ii) Executives awareness programme.

iii) Announcement by management about TPM.

iv) Selection of model equipments (one to three depending upon size of the organization.

• Intial education and propaganda

i) Trainers training programme - Phase-I

ii) Preparation of TPM propagation material/hand bills etc. (QCFI may help in this)

iii) Visit to some unit implementing TPM

iv) Awareness programme to all employees by Trainers. Employees of model equipments area will be trained in presence of QCFI faculty.

v) Training programme of middle management executives of model areas (along with trained trainers).

vi) Practical demonstration for model equipments.

• Setting up TPM and departmental committee t Formation of TPM secretaries, 8 pillars of TPM and meeting with each pillar to guide them about their roles.

• Establishing TPM working system t Analysing present way of functioning present achievements, benchmark and what to be achieved (target) to be set by each committee chairman and approved by TPM steering committee, calculation of OEE.

• Master plans for institutionalizing TPM by each committee and finalized by steering committee.

Stage B: Initial implementation stage

• Starting TPM or kick off

i) Prepare presentation of achievements of model equipments taken.

ii) Propagation of the ceremony

iii) Kick off ceremony Stage

Stage C: Full implementation or full development stage

• Monthly guidance by QCFI

• Trainers training programme phase II (who will help implantation of TPM)

• Establishing initial control system for new product and equipments.

• Establishing quality maintenance organization (Hinshitsu Hozen; with the help of trainers)

• Establishing systems to improve efficiency of administrations and other indirect department (with the help of trainers).

• Establishing systems to control safety, sanitation and working einvironment. Stage D: Maturity of institutionalizing stage

• Bi-monthly audit for guidance and help

• Getting QCFI-TPM award (Visit by QCFI team for three days to check the status).

• Apply for other awards.

		TOTAL PRODUCTIVE MAINTENANCE 1. Technical advancement has made the world today a border-less society. Along with that competition has also intensified. Today’s competition is ruthless and survival depends upon not only on continuous improvement and invention of new products but also on their availability at low cost, timely delivery, courteous sales and prompt after sales service. 2. Industries use many precision instruments and devices which help in monitoring and controlling raw material quality and consistency, functional efficiency of equipment and their accuracy, auto operational systems to minimize and/or to avoid variations in the methods used and POKA YOKE /Mistake proofing system to eliminate human errors. 3. Even though they all help, upkeep of equipment has become an additional responsibility. Care for equipment and allied systems have become a great need. Total Productive Maintenance (TPM) precisely meets this need. 4. By adopting TPM we can make even old machinery and systems to function trouble free. Zero failure, zero defect, zero accident and zero pollution are need of the hour and TPM helps in achieving this. 5. TPM is to maximize equipment effectiveness by establishing a thorough system of ‘Productive Maintenance’ (PM) for the entire life span of the equipment. It is implemented by various departments like engineering; production, maintenance etc., and involves everyone in the organisation. It is based on the idea of promotion of PM through autonomous small group activities. 6. TPM has now within its fold, to Zero breakdown to Zero defect to Zero accident and to Zero pollution as its goals. 7. TPM has been found to be benefiting all areas i.e. in production, quality, cost, delivery, safety and morale. In case of labour productivity, value added per person and rate of operation etc., increases and breakdown become nil or considerably less. As far as quality is concerned defects in process material as well as in processed material reduce and so also claims from customers. There will be reduction in manpower cost, maintenance cost and also results in energy conservation. As far as delivery is concerned, it leads to reduced stock and increased inventory turn over. Roadmap recommended and used by QCFI for this. Stage A: Preliminary or preparation stage to Top Management programmes i) Senior Executives awareness programme. ii) Executives awareness programme. iii) Announcement by management about TPM. iv) Selection of model equipments (one to three depending upon size of the organization. • Intial education and propaganda i) Trainers training programme - Phase-I ii) Preparation of TPM propagation material/hand bills etc. (QCFI may help in this) iii) Visit to some unit implementing TPM iv) Awareness programme to all employees by Trainers. Employees of model equipments area will be trained in presence of QCFI faculty. v) Training programme of middle management executives of model areas (along with trained trainers). vi) Practical demonstration for model equipments. • Setting up TPM and departmental committee t Formation of TPM secretaries, 8 pillars of TPM and meeting with each pillar to guide them about their roles. • Establishing TPM working system t Analysing present way of functioning present achievements, benchmark and what to be achieved (target) to be set by each committee chairman and approved by TPM steering committee, calculation of OEE. • Master plans for institutionalizing TPM by each committee and finalized by steering committee. Stage B: Initial implementation stage • Starting TPM or kick off i) Prepare presentation of achievements of model equipments taken. ii) Propagation of the ceremony iii) Kick off ceremony Stage Stage C: Full implementation or full development stage • Monthly guidance by QCFI • Trainers training programme phase II (who will help implantation of TPM) • Establishing initial control system for new product and equipments. • Establishing quality maintenance organization (Hinshitsu Hozen; with the help of trainers) • Establishing systems to improve efficiency of administrations and other indirect department (with the help of trainers). • Establishing systems to control safety, sanitation and working einvironment. Stage D: Maturity of institutionalizing stage • Bi-monthly audit for guidance and help • Getting QCFI-TPM award (Visit by QCFI team for three days to check the status). • Apply for other awards.

TOTAL PRODUCTIVE MAINTENANCE