Total Productive Maintenance Consultants

Achieve Higher Quality, Fewer Defects & Lower Manufacturing Cost with us.

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 manufacturing, they can produce their product in LESS TIME, LESS COST, ZERO LOSS, without affecting quality of the product.

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

Ready to get started but not sure where to begin ? Let’s figure it out together.

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% while maintaining product quality

Delivery

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

Safety

Sustain a workplace free from accidents and injuries.

Moral

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

Want to Start TPM in your Organization ?

Our TPM Consulting approach 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

Training and Education

-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.

Early Equipment Management

-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.

What is JIPM Certification in TPM?

The Japan Institute of Plant Maintenance (JIPM) offers Total Productive Maintenance (TPM) certification that indicates expertise in reducing downtime and improving equipment effectiveness. JIPM certification validates the excellence in maintenance and offers long term skills to professionals for sustainable growth and operational efficiency. Autonomous, planned, quality maintenance, and targeted improvement are all covered in JIPM TPM Certification training. The purpose of JIPM certification is to validate one’s ability to apply and manage TPM techniques that improve production processes and cut downtime.

How JIPM Do Their TPM certification?

Below is the list of point that follows in JIPM TPM Certification:

Declaration by Top Management Introduce TPM
Education and Campaign to Introduce TPM
Establishment of a TPM Promotion Organization and Formal Organization Model
Setting the Basic Policy and Goals of TPM
Creating a TPM Master Plan
TPM Kickoff and PR
1. Kobetsu Kaizen (Individual Improvement)
2. Jishu Hozen (Autonomous Maintenance)
3. Keikaku Hozen (Planned Maintenance)
4. Upgrading Operation and Maintenance Skills
Initial Phase Control (Product)
Initial Phase Control (Equipment)
Hinshitsu Hozen (Quality Maintenance)
Office TPM
Safety, Health and Environment Management System
Thorough Implementation and Continuous Improvement of TPM

How Tetrahedron Helps in JIPM TPM Certification

Tetrahedron Manufacturing Services specializes in providing consultancy to achieve JIPM TPM certification. We have a tailored consultant that ensures compliance with JIPM Standards, improves workflows, reduces downtime, etc. Improve your company’s work performance with our proficiency in TPM technique and concepts.

Project Preparation
Leadership Development
Education and Training
Data Monitoring
Performance Evaluation
Effectiveness Measurement
Certification Readiness

Case Study

Total Productivity Maintenance in Leading uPVC, CPVC, PPR-C 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

– 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

TMS Team Approach

– Focus on Total Productive Maintenance

– Focus on Quality

– Focus on Employee engagement and Improvement

– Lean Six Sigma

– Overall Equipment Effectiveness (OEE)

– Safety Policy

– Inventory reduction

– Customer service

Result Achieved

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

– Increase in 5S score to 80%

– Increase in Line efficiency by more than 20%

– Increase in Skill Score Improvement by 30%

– Reduction in change over time by more than 70%