Total Productive Maintenance Consultants

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tpm total productive maintenance

TPM (Total Productive Maintenance) is a culture that focuses on improving the effectiveness of the plant, equipment and processes through the empowerment of people to achieve perfect production.

TPM emphasises proactive and preventative maintenance to maximise the operational efficiency of equipment. It blurs the distinction between the roles of production and maintenance by placing a strong emphasis on empowering operators to help maintain their equipment.

Getting operators involved in maintaining their own equipment, and emphasising proactive and preventive maintenance will lay a foundation for improved production (fewer breakdowns, stops, and defects).

Why Company choose TPM approch

Before TPM implementation Operator only use the machine and the maintenance person is responsible for daily maintenance due to which maintenance persons don’t get enough time for preventive maintenance. After successfully implementing TPM in organization they can Produce or product in LESS TIME, LESS COST, ZERO LOSS, WITHOUT affecting Quality of the product by INVOLING the satisfied employee.

Advantages of TPM Approach

The goal of TPM is to Increase production as well as improve the moral and job satisfaction of employees.Through achieving -ZERO FAILURE, ZERO LOSS, ZERO DEFECT, ZERO ACCIDENT

Advantages of TPM

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Productivity

TPM Consultant

Obtain a Minimum 90% OEE (Overall Equipment Effectiveness)

Quality

Operate in a manner, so there are no customer complaints

Cost

Reduce the manufacturing cost by 30%

Delivery

Achieve 100% success in delivering the goods as required by the customer

Safety

Maintain a accident free environment

Moral

Increase the suggestions by 3 times Develop Multi-skilled and flexible workers

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Our TPM Consultanting approch for 8 Pillars of TPM

Individual Improvement

  • -Set Improvement Themes and Targets

  • -Select Model Equipment, Line and Process

  • -Organize Project Teams

  • -Understand Present Losses (OEE)

  • -Set Improvement Themes and Targets

  • -Draft Improvement Plan

  • -Perform Analysis and Draft and Evaluate Countermeasures

  • -Implement Improvement

  • -Confirm Results

  • -Take Measures to Prevent Recurrence

  • -Horizontal Replication

Autonomous Maintenance

  • -Machine Ownership- Gives operators greater “ownership” of their equipment.

  • -Initial Cleaning- Places responsibility for routine maintenance, such as cleaning, lubricating, and inspection, in the hands of operators

  • -Increases operators’ knowledge of their equipment..

  • -Identifies emergent issues before they become failures.

  • -Frees maintenance personnel for higher-level tasks.

  • -Identify Source of Contamination (SOC) identification

  • -Hard to access area (HTTA) identification

  • -General Inspection

  • -CLIT

  • -Standardization

Planned Maintenance

  • -Set Improvement Themes and Targets

  • -Select Model Equipment, Line and Process

  • -Organize Project Teams

  • -Understand Present Losses (OEE)

  • -Set Improvement Themes and Targets

  • -Draft Improvement Plan

  • -Perform Analysis and Draft and Evaluate Countermeasures

  • -Implement Improvement

  • -Confirm Results

  • -Take Measures to Prevent Recurrence

  • -Horizontal Replication

Upgrading Operation and Maintenance Skill

  • -Fill in knowledge gaps necessary to achieve TPM goals.

  • -Applies to operators, maintenance personnel and managers.

  • -Operators develop skills to routinely maintain equipment and identify emerging problems.

  • -Maintenance personnel learn techniques for proactive and preventative

    maintenance.

  • -Managers are trained on TPM principles as well as on employee coaching and development.

Initial Phase

  • -New equipment reaches planned performance levels much faster due tofewer startup issues.

  • -Directs practical knowledge and understanding of manufacturing

    equipment gained through TPM towards improving the design of new

    equipment.

  • -Maintenance is simpler and more robust due to practical review and

    employee involvement prior to installation.

Quality Maintenance

  • -Design error detection and prevention into production processes.

  • -Apply Root Cause Analysis to eliminate recurring sources of quality defects.

  • -Specifically targets quality issues with improvement projects focused on

    removing root sources of defects.

  • -Reduces number of defects.

  • -Reduces cost by catching defects early (it is expensive and unreliable to find

    defects through inspection).

Office TPM

  • -Apply TPM techniques to administrative functions.

  • -Extends TPM benefits beyond the plant floor by addressing waste in administrative functions.

  • -Supports production through improved administrative operations (e.g.

    order processing, procurement, and scheduling).

Health, Safety & Environment

  • -Maintain a safe and healthy working environment.

  • -Eliminates potential health and safety risks, resulting in a safer workplace.

  • -Specifically targets the goal of an accident-free workplace.

Case Study

Total Productivity Maintenance in Leading Upvc CPVC Pipes & Fittings Manufacturer

Background

The company is one of the major piping solution providing company with strong brand value Domestically & Internationally . Today, they have a PAN India footprint with strong customer hold in Northern India with more than 3 decades of experience in the Indian Pipe Market. The company started manufacturing UPVC Pipes in the year 2000, with a capacity of 3600 MT per annum. Since then, the company has undergone massive manufacturing and distribution expansion 2400 MT per annum of CPVC Pipes and a wide range of other high-end related products.

Challenges Before Tetrahedron 

-Max. OEE was 45%

-Customer Complaint was 20 + per month

-Skill score was below 30%

-No Safety Practices by Employees

-Lower productivity of manpower due to additional manpower required to run overtime

-No Tracking MTTR & MTBF Data

-No BDA(Breakdown Analysis) was done

-No analysis of repeated breakdown cases

-PM plan adherence to 40%

-Machine wise PM checklist were not available

-Machine basic conditions are not up to mark

-Hard to access area not identified

-Source of contamination was not identified

 

TMS Team Approach

Tetrahedron ‘s Consulting team visited the Client site. Then drafted a 18 months plan to Implement TPM. TMS initiated the journey by engaging employees through Individual Improvement tools like 5S, KAIZEN. Then achieved significant Result and appreciation from client

Result Achieved

TMS Consultant trained the team to implement a planned maintenance system to improve MTTR & MTBF score

TPM Consultant

– improved machine condition

– Improved skill level of the operators

– Subsequently improved operational parameters like Breakdown, Quality, Safety, Education and skill level of employees

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