Professional Documents
Culture Documents
ABSTRACT
The manufacturing industry has gone through Keywords: 5S, Continuous Improvement(Kaizen),
significant changes in the last decade. Competition Manufacturing Excellence, Lead Time Reduction /
has increased dramatically. Customers focus on Throughput time Reduction, Productivity, Total
product quality, product delivery time, safety and cost Productive Maintenance (TPM) ,Human factors,
of product. Because of these, company should Resistance to change.
introduce a system to improve and increase
quality, productivity and safety continuously. The Introduction
aim of this paper is to study the Human Aspects in
Implementation of Total Productive Maintenance. In TPM is an innovative Japanese concept. Total
this
his paper, we have taken the case study to Productive Maintenance (TPM) is most important
demonstrate the Total Productive Maintenance concept for industrial application. The TPM literature
lit
implementation methodology and to highlight the offers a number of definitions for Total Productive
benefits achieved during Total Productive Maintenance viz. TPM is the general movement on
Maintenance in an engineering industry XYZ Pvt. the part of businesses to try to do more With less.
Ltd. (name changed) situated in Indore, Madhya (Lawrence 1999 p. 63). TPM is an integrated life- life
Pradesh. TPM proved that its implementation cycle approach to factory maintenance and Support.
Sup
helped the company significantly to achieve higher (Blanchard 1997 p. 72) TPM is a program that
Productivity, Quality, Cost, Delivery, Safety, “addresses equipment maintenance through a
Morale, customer satisfaction and profits or the Comprehensive productive--maintenance delivery
improvements in key performance indicators system covering the Entire life of the equipment and
(PQCDSM). Based on the analysis for achieving involving all employees from production and
operational excellence 5S, LeadTime Reduction / maintenance personnel el to top management. (Mc-(Mc
Throughput time Reduction, Kaizen and Kone, Schroeder etal. 1999 p. 123) TPM is a way of
preventive maintenance are important.
portant. Whereas working together to improve equipment
Poka-Yoke
Yoke and visual control are necessary effectiveness.(Society of Manufacturing Engineers
activities for implementation of Total Productive 1995 p. vii)TPM is a methodology and philosophy of
Maintenance. strategic equipment .Management focused on the goal
of building product quality by Maximizing equipment
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International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470
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International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470
time due to equipment failure is considered waste and system is usually developed and implemented. The
non-value-added time. A dirty area can also goal of the sustain step is to ingrain the 5S process
contribute to safety issues that have the potential to into the company culture. The company must strive to
cause a worker to be injured. Operators should clean make 5S a way of life so the benefits gained through
their areas at the end of each shift. By doing this they the exercise can be maintained. 5S is not a one-time
will likely notice anything out of the ordinary such as exercise. Following the 5S Process must become a
oil or lubricant leaks, worn lift cables, burnt out bulbs, habit.
dirty sensors, etc. The purpose is to reduce waste and
improve operator safety and efficiency. Action plan
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International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470
Implementation example
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International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470
startingphase of the implementation. It was not so Typically people show strong resistance to
clear where to start, because the model was totally change.Many people treat it just another “Program of
new. When things go started the implementing the month ” without paying any focus and also doubt
continued quite smoothly. about the effectiveness. Not sufficient resources
(people, money, time, etc.) and assistance provided
Problem Statement Insufficient understanding of the methodology and
philosophy by middle management TPM is not a
One of the difficulties in implementing TPM as a
“quick fix ” approach, it involve cultural change to the
methodology is that it takes a considerable number of
ways we do things Departmental barrier existing
years. The time taken depends on the size of the
within Business Unit Many people considered TPM
organization. There is no quick way for implementing
activities as additional work/threat.So by using
TPM. This is contradictory to the traditional
fishbone (Ishikawa) Figure-Fishbone diagram
management improvement strategies. Following are
following reasons were found.
the other difficulties faced in TPM implementation.
Figure-Fishbone diagram
Results & discussion is always a positive one, employees not always see it
that way. For that reason, during the first training
Tpm is a top-down approach and never a down-up sessions we will find resistance, especially from the
approach. Tpm requires an office and not a facilitator. least educated people. In order to overcome these
Tpm is a long term approach not short term. Tpm is attitudes, we must create an environment of trust and
all about people and not machines. Tpm is not good will. It is important to create a flow of
culture bound.tpm will require a budget. Tpm and communication with operators, supervisors, managers
company goals must be aligned. management etc. When they perceive our sincere purpose of
commitment and not support. Tpm is all about people providing them with a better equipment and working
and not machines. Tpm is not culture bound. environment, most of the barriers will be brought
Management sees Tpm as a cost centre. Lack of tpm down. Sometimes we will find that the production
knowledge. TPM faces the natural reaction that we all foremen are not willing to give up their people for the
develop against CHANGE. As a matter of fact, any effort because they have a heavy work load. They still
change or alteration in our lives is always a source of think of the maintenance guys taking care of
concern. TPM represents a change and even though it
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International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470
everything, the “I break it-you fix it” approach. REFRENCES
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