Esprit Rock

Total Productive Maintenance

Total Productive Maintenance (TPM) is an initiative taken for people to know the importance of production and maintenance in manufacturing. It also increases employee job satisfaction. It improves the income of the business and generate physical assets. TPM is required in a manufacturing company for its good maintenance.
The objectives of TPM are:
• To achieve no defects, no breakdowns and no accidents.
• Form groups and to decrease defects and self-maintenance.
• Involving all the levels in an organization.
The motives of TPM are:
• Adoption of life cycle approach for improving the overall performance.
• Job enlargement and satisfaction among the employees by increasing productivity.
• Teams for identifying failures and any modifications to be done in the plants.
The Benefits of TPM are:
• Satisfaction of the customers and employees.
• Reduced accidents and complaints.
• Increase in plant efficiency.
• Reduction in manufacturing costs.
• Achieving all the goals and objectives of the teams.
• Creating enthusiastic work environment.
The Aims of TPM and pursuing ‘the five goals’ are:
• Improving equipment efficiency: Examining the equipment and understanding the reasons for loss that is downtime loss, defect loss, speed loss.
• Achieving independent maintenance: The people operating take responsibility for maintenance. The repair level, here the staff carries out instructions. The prevention level, where staff takes actions to prevent problems. The improvement level, the staff takes actions and suggest improvements.
• Planning maintenance: A systematic way is required to maintain activities. It includes maintenance of equipment, creating standards and maintaining staff. It is a supporting responsibility. It includes diagnosing the problems and evaluating maintenance practice.
• Training staff in applicable maintenance skill: The responsibilities require all operating and maintenance roles. It requires continuous training.
• Achieving equipment management: Maintenance prevention is the major aim. TPM tracks maintenance problems and try to eliminate them.
Assuming TVS Motors, a manufacturing company needs total productive maintenance. The process of TPM would be-
i. Announcing the TPM in TVS Motors meetings and giving an introduction to the organization about the benefits of TPM. It should also be published in the letter to the shareholders, and informed to the board.
ii. The aim of the company through TPM should be announced and explained to the employees and they should be given the required training and assistance.
iii. Separate teams and groups should be made in order to distribute all the work related to TPM and to make sure it is done properly. For example the team to handle the TVS equipment, maintain quality of work, including improvement etc.
iv. Establishing benchmarks, targets and goals for the company through TPM.
v. Implementing the TPM plans and achieving maintenance prevention.
vi. Make sure all the activities are implemented and established. Also as they reach a maturity stage after a point, we can evaluate the progress and benefits made.
In today’s competitive world, evolving the TPM initiative needs continuous development techniques to ensure that it employees do not become complacent. It should be kept fresh my initiating new ideas and keeping the objectives new and motivating. Evolving the plans also assists to guarantee that it succeeds over the long-term by constantly adapting it to a changing new environment.