CIA-3 Component 1

TPM Group activity

Enterprise Asset Management

By

Darren Joseph (1727911)

M K Sai Charan (1727924)
Illa Anjali (1727942)
Sandhya Gopinath (1727956)
Vaishnavi Nair (1727960)

Institute of Management
CHRIST (Deemed to be University)
 Q.1 Objectives of TPM Club of India.Major activities.
 Being a National Focal Point of reference for JIPM - TPM activities
 Promote JIPM-TPM by disseminating information through Seminars, Conferences, Training
programmes, Newsletters etc.
 Assist industry to implement JIPM-TPM through counseling & training
 Contribute to understanding of JIPM-TPM through research & development

Major acivities of TPM Club of India

Workshops
 Specific programmes are organized which would be useful to the Industry.Companies nominate their
personnel for these seminars and workshops.
Conferences
 Carefully designed to share the best practices of different companies as adopted by them on a common
platform – a chance to interact with companies who have achieved excellent results using TPM
methodologies
In-house Counselling and Training
 A proven model of combined Counselling and Training programme to provide knowledge and skill with
appropriate sharing of examples.
Competition
 To motivate and encourage the members of TPM Club India, Competitions are being organized to get
maximum benefit.
 Kaizen Competition - Best kaizens successfully implemented competes for the trophies under different
categories.
 TPM Circle Competition – Best circle activities are spread through this platform and the best ones take the
trophy.
 3M Competition – Best projects on Muda, Mura & Muri being presented nationally.
 Poka Yoke Competition - Best ‘Mistake Proofing’ pretentions being presented..
 Champions' Trophy – To find the Champions among all the winners from various Competitions.

Information exchange

o Books - Based on the methodology of JIPM-TPM and the vast experience of our counselors;
books relevant to the Industry are prepared and published from time to time.
o Newsletters – to communicate to many people; newsletter are circulated
o Website – our website www.tpmclubindia.org is used as a tool to communicate information on
TPM to the industry.
Certification Courses

5 day In-depth TPM Facilitators course - To understand, assimilate and implement TPM inside
any organization, calls for a firm comprehension of the principles and methods of the various pillar
activities, by the secretariat, since it is they who have to ensure a structured way of TPM
implementation. Depending upon the size of the organization, a minimum of two persons would
be required to possess this knowledge, to deploy among the operating teams, middle and senior
management alike.

Q.2 Major elements of a good TPM Program

TPM Key Element 1: Improving equipment effectiveness by targeting the major losses. TPM
activities should focus on results. One of the fundamental measures used in TPM is Overall
Equipment Effectiveness (OEE) which includes the major losses that TPM seeks to eliminate. OEE
= Equipment Availability x Performance Efficiency x Rate of Quality.

TPM Key Element 2: Involving operators in daily maintenance of their equipment. Operator
involvement must be defined in ways that make sense in your work culture. There are tasks that
operators can do without using any tools: Clean and inspect equipment. Maintenance people can
teach the operators what to look and listen for.

TPM Key Element 3: Improving maintenance efficiency and effectiveness. This means improving
all aspects of maintenance including spare parts, computerized maintenance management system,
preventive maintenance, predictive maintenance, maintenance tools, work order system, planned
and scheduled maintenance, and equipment histories. These are all part of TPM. They can’t be
separate or on the side. They must be woven in. For example, production, maintenance,
purchasing, and shipping and receiving should use a computerized maintenance management
system. It’s not just a maintenance management system anymore; it’s an equipment information
management system.

TPM Key Element 4: Training to improve the skills of everyone involved. This means maintenance
training, operations training, leadership training, training about root cause analysis of the major
losses, reliability training, etc. The training should first address the very basic needs of the people
and the equipment targeted for TPM. One of the most important basic training needs for TPM is
designed to help the people involved understand what TPM is and why it is so important for the
equipment and the business.

TPM Key Element 5: Life-cycle equipment management and maintenance prevention design. If
you’re going to design and develop new equipment or a major modification, involve those who
are going to operate it and maintain it for the next 5, 10, or 15 years in the process. Use their ideas
to make it easier to operate and easier to maintain.

TPM Key Element 6: Wining with teamwork focused on common goals. Even with all of the
emphasis on high-performing equipment the best equipment cannot consistently perform well
without teamwork focused on common goals using common processes. In TPM the sense of
teamwork centers around the targeted equipment, then expands through all areas using TPM to
improve their performance.

Q-3 Companies that implemented TPM and benefits accrued by them

Company Name- Hero Moto Corp Ltd Dharuhera Plant

Year-2011

Benefits achieved

Productivity

 Avg. Production of Vehicles/Day increased by 41

 Productivity of Man /Vehicle/Day increased 14%

Quality

 Customer Complaints reduced by 71%

Delivery

 MTBF increased by 500%

 Breakdown Frequency reduced by 85%
Morale

 No. of Suggestion/Man/Year increased by 104%

 Accidents per million man hours worked reduced by 93%

Awards

Award for TPM Excellence – First Category

Company

The Supreme Industries Ltd, Pondy

Year

2011

Benefits achieved

Production

 Production increased by 52%

 OPE increased by 85%
 Breakdowns reduced by 93%

Quality

 Customer Complaints reduced by 100%

Cost

 Total maintenance cost reduced by 58%

SAFETY

 Major accidents:ZERO

Morale
  Overall training: mandays per month increased to 6.25 from 2.8

Awards

 Award for TPM Excellence - First Category

Turbo Energy Limited Pulivalam

Benefits

 OEE increased to 85%

 Breakdown reduced by 90%
 In house rejection reduced by 88%
 Maintenance Cost reduced by 48%
 Raw material inventory reduced by 32%
 Major and Minor Accident achieved ZERO

Q.4 track record of Indian companies wrt bagging international awards pertaining to PM
Maintainance.

Award for
Award for
Award for TPM Award for
TPM
TPM Excellence in TPM
Excellence in
Sl. Excellence - Consistent Excellence - Special
Company Name Consistent
No. Second TPM First Award
TPM
Category / Commitment - Category /
Commitment /
Category B Second Category A
First Category
Category
ABI Showatech
(India) Ltd, Brake
Master Cylinder
1 2007
Manufacturing Plant
in Pulivalam ,
Sholinghur
2 Aditya Cements 2001
Apcotex Industries
3 2011 2013
Ltd Taloja Plant
AQUA Group,
4 Aquapump 2009
Industries, Aquasub
 Engineering (Unit I,
II, III, IV)
Aradhana Soft
5 Drinks Company, 2008
Panipat Plant
Asahi India Glass
Ltd, Auto Glass
6 2010
Division, Bawal
Plant
Badve Engineering
7 2013
Ltd., Polymer Plant
Bajaj Auto Ltd,
8 2005
Akurdi Plant, Pune
Bajaj Auto Ltd,
9 2006
Chakan
Bajaj Auto Ltd,
Commercial Vehicle
10 Division (CVD), 2006 2012
Waluj Plant,
Aurangabad
Bajaj Auto Ltd,
Motorcycle Division
11 2012
(MCD), Waluj Plant,
Aurangabad
Bajaj Auto Ltd,
12 2011
Pantnagar Plant
13 Balasore Alloys Ltd 2006 2008
Bharat Seats Ltd,
14 2006
Gurgaon Plant
15 Birla Tyres, Balasore 2000
Brakes India Ltd -
16 Foundry Division, 2003 2005 2007
Sholinghur
Brakes India Ltd,
17 Brake Division, 2003 2005 2008
Sholinghur
Brakes India Ltd,
18 2005 2007
Nanjangud
Brakes India Ltd,
19 2003 2005 2007
Padi Plant
 Brakes India Ltd,
20 2004 2005 2010
Polambakkam
Chennai Petroleum
Corporation Ltd,
21 2009 2011
Cauvery Basin
Refinery
Chennai Petroleum
22 Corporation Ltd, 2010
Manali Refinery
Dattatreya Textile
23 2004
Pvt Ltd
Delphi-TVS Diesel
24 2005
Systems Ltd
Electrosteel Castings
25 Ltd, Khardah Works, 2008 2010
Kolkata
Emami Paper Mills,
26 2006 2008
Balasore
Endurance
Technologies Pvt
Ltd, (Clutch Div -
27 Waluj), High 2013
Technology
Transmission
Systems (I) Pvt Ltd
Endurance
Technologies Pvt
28 2013
Ltd, B-2, Casting
Div., Aurangabad
Endurance
Technologies Pvt
29 2013
Ltd, Braking
Division
Endurance
Technologies Pvt.
Ltd (Suspension
30 2011
Division) Plot No.
K-228/229 & E-
92/93
Endurance
Technologies Pvt.
31 2011
Ltd L6/3 - Casting
Division
 Exide Industries Ltd
32 SF Division, Taloja 2011
Plant
Exide Industries Ltd,
33 2010
Chinchwad
Exide Industries Ltd,
34 2008
Haldia Factory
Exide Industries Ltd,
35 2010
Hosur Plant
Fenner (India) Ltd,
36 2010
Hyderabad Plant - 1
Fenner (India) Ltd,
37 2010
Madurai Plant - 1
Galaxy Surfactants
38 2003 2007
Ltd, Taloja Plants
Galaxy Surfactants
39 2003
Ltd, Tarapur Plants
Godrej & Boyce Mf.
40 Co. Ltd., Godrej 2013
Precision Systems
Godrej Consumer
41 Products Ltd, 2006
Malanpur
Gontermann-Peipers
42 2007 2010
(India) Ltd
Hero MotoCorp Ltd,
43 2011
Dharuhera Plant
Hero MotoCorp Ltd,
44 2012
Gurgaon Plant
Hero MotoCorp Ltd,
45 2012
Haridwar Plant
Hi Tech Carbon Ltd,
46 2003 2004
Gummidipoondi
Hi Tech Carbon Ltd,
47 2004
Renukoot
Hindustan Coca-
48 Cola Beverages Pvt 2013
Ltd., Moula Ali Plant
Hindustan Coca-
49 Cola Beverages Pvt 2013
Ltd., Srikalahasthi
 Hindustan Lever Ltd,
50 Beverages Factory, 2005
Pondicherry
Hindustan Lever Ltd,
51 2001 2005
Chindwara
Hindustan Lever Ltd,
52 2003
Chiplun Plant
Hindustan Lever Ltd,
53 2002
Daman Detergents
Hindustan Lever Ltd,
54 2006
Hosur
Hindustan Lever Ltd,
HPC DIV-
55 2004
Detergents Factory,
Pondicherry
Hindustan Lever Ltd,
56 2005
Kalwa Factory
Hindustan Lever Ltd,
57 2005
Kandla Factory
Hindustan Lever Ltd,
58 Khaliabad Beverages 2004
Factory
Hindustan Lever Ltd,
59 Kidderpore 2004 2006
Beverages Factory
Hindustan Lever Ltd,
60 2002 2004 2006
Mangalore
Hindustan Lever Ltd,
61 Mysore Beverages 2004
Factory
Hindustan Lever Ltd,
62 2002 2004
Orai
Hindustan Lever Ltd,
63 Personal Products, 2001 2004
Dadra
Hindustan Lever Ltd,
64 Personal Products, 2003 2005
Pondicherry
Hindustan Lever Ltd,
65 2002
Rajpura
 Hindustan Lever Ltd,
66 2003 2005
Silvasa Beverages
Hindustan Lever Ltd,
67 2003 2005
Silvasa Detergents
Hindustan Lever Ltd,
68 2000 2002
Sumerpur
Hindustan Lever Ltd,
69 2005
Tatapuram Factory
Hindustan Lever Ltd,
70 Toilet Soap Factory, 2004 2006
Goa
Hindustan Lever Ltd,
71 Western Regional 2004
Office
Hindustan Lever Ltd,
72 2002
Yavatmal
Hindustan Motors
Ltd (AVTEC Ltd,
73 2003 2005
Power Plant,
Pithampur)
Hindustan Unilever
74 Ltd, Haldia 2005 2007
Detergents Factory
Hindustan Unilever
75 2003 2005 2007
Ltd, Khamgaon
Hindustan Unilever
76 2007
Ltd, Nashik Factory
Hindustan Unilever
77 Ltd, Pune Tea 2007
Exports Factory
Hi-Tech Gears Ltd
(Group), Hi-Tech
Gears Ltd and
78 Getrag Hi-Tech 2009 2011
Gears (India) Pvt Ltd
(Bhiwadi), Hi-Tech
Gears Ltd (Manesar)
79 Hospet Steels Ltd 2007
Indian Oil
80 Corporation Ltd 2011 2013
(Assam Oil
 Division), Digboi
Refinery
Indian Oil
81 Corporation Ltd, 2008 2011
Barauni Refinery
Indian Oil
82 Corporation Ltd, 2012
Bongaigaon Refinery
Indian Oil
83 Corporation Ltd, 2009
Guwahati Refinery
Indian Oil
84 Corporation Ltd, 2010
Haldia Refinery
Indian Oil
85 Corporation Ltd, 2008 2012
Panipat Refinery
Indo Gulf Fertilizer
86 2000 2002
Ltd
Ispat Industries Ltd,
87 2006 2008
Dolvi
Ispat Industries Ltd,
88 2006 2008
Kalmeshwar
J K Paper Ltd,
89 2006 2009
Central Pulp Mills
J K Paper Ltd, J K
90 Paper Mills, 2006 2009
Jaykaypur
Jamshedpur Utilities
91 and Services 2008
Company Ltd
Jindal Stainless Ltd,
92 2004
Hisar
JK Tyre & Industries
93 Ltd, Banmore Tyre 2010
Plant
JK Tyre & Industries
94 Ltd, Kankroli Tyre 2010
Plant
JK Tyre & Industries
95 Ltd, Vikrant Tyre 2010
Plant, Mysore
 LAP-Ross
96 2013
Engineering Ltd
Light Alloy Products
97 2013
Ltd
Lumax DK Auto
98 Industries Ltd, 2012
Pantnagar
Mahindra &
99 Mahindra Ltd (Auto 2003
Div.), Mumbai
Mahindra &
Mahindra Ltd, Farm
100 2010 2012
Division, Mumbai
Plant
Mahindra &
Mahindra Ltd, Farm
101 2010 2012
Division, Nagpur
Plant
Mahindra &
Mahindra Ltd, Farm
102 2010 2012
Division, Rudrapur
Plant
Mahindra &
Mahindra Ltd, Farm
103 Equipment Sector, 2012
Swaraj Division -
Plant 1
Mahindra &
Mahindra Ltd, Farm
104 Equipment Sector, 2012
Swaraj Division -
Plant 2
Minda Industries Ltd
105 Switch Division, 2011
Pune
MRF Ltd - Arkonam
106 2008
Unit
107 MRF Ltd - Goa Unit 2008
MRF Ltd - Kottayam
108 2011
Unit
Mukand Ltd, Kalwe
109 2005
Steel Plant
110 Mukand Ltd, MBD 2003
Munjal Showa Ltd,
111 2008 2013
Gurgaon Plant
Munjal Showa Ltd,
112 2010
Manesar Plant
National Engineering
113 2008
Industries Ltd, Jaipur
National Engineering
114 Industries Ltd, 2007
Newai Plant
Orient Cement
(Props: Orient Paper
& Industries Ltd),
115 2012
Orient Cement,
Clinker Grinding
Unit (CGU)
Orient Cements,
116 Devapur Cement 2001 2003
Works
PepsiCo India
Holdings Private Ltd
117 2008
(Fritolay Division),
Channo Plant
PepsiCo India
Holdings Private
118 Ltd, Frito Lay 2009 2012
Division, Kolkata
Plant
PepsiCo India
119 Holdings Pvt. Ltd, 2011
Pune Foods Plant
QH Talbros Ltd,
120 2011
IMT Manesar
Raychem RPG (P)
Ltd International
121 2011
Business Division,
Vasai
Showa Engineering
122 Ltd, 2007
Melvenkatapuram
Shriram Pistons &
123 2004 2007
Rings Ltd
 Sona BLW Precision
124 Forgings Ltd, 2011 2013
Gurgaon Plant
Sona BLW Precision
125 Forgings Ltd, Pune 2013
Plant
Sona Koyo Steering
126 Systems Ltd, 2007
Gurgaon
Sona Somic
Lemforder
127 2011
Components Ltd,
Gurgaon Plant
Sundaram Clayton
128 Ltd, Brakes Division, 2007
Plant 2
Sundaram Clayton
129 Ltd., Die Casting 2013
Div., Hosur Plant
Sundaram Industries
130 2004 2006 2008
Ltd - Rubber Factory
Sundaram Textiles
131 2005
Ltd, Nanguneri Unit
Sundaram-Clayton
132 2009
Ltd, Padi Plant
Sundram Fasteners
133 1998 2005 2007
Ltd, Hosur
Sundram Fasteners
134 Ltd, Krishnapuram 2004 2008
Plant
Sundram Fasteners
135 2004
Ltd, Padi
Sundram Fasteners
136 2005 2007
Ltd, Pondicherry
137 Tanfac Industries Ltd 1999 2002
138 Tata Cummins Ltd 2005
Tata Metaliks,
139 2002 2005
Kharagpur
Tata Sponge Iron
140 2012
Ltd, Joda
 TATA Steel
Processing and
141 Distribution Ltd, HR 2009
Plant & CR Plant,
Jamshedpur
Telco Construction
Equipment Co. Ltd
142 2010 2013
(TELCON),
Dharwad
Telco Construction
Equipment Co. Ltd
143 2010
(TELCON),
Jamshedpur
Tetra Pak India
144 Private Ltd, Tetra 2006 2008
Pak, Pune
The Supreme
145 Industries Ltd, 2011 2013
Pondicherry Plant
The Tata Iron &
146 Steel Co Ltd, 2004
Bearings Div.
The Tata Iron &
147 Steel Co Ltd, Hot 2004
Strip Mill
The Tata Iron &
Steel Co Ltd,
148 2004
Precision Tube Mill,
Tube Div.
The Tata Iron &
149 Steel Co Ltd, Wire 2004
Rod Mill
The Tinplate Co. of
150 India Ltd, Golmuri 2005
Works
Titan TimeProducts
151 2007
Ltd
Tractors and Farm
Equipment Ltd,
Engineering Plastics
152 2012
and Tool Room
Division, DBR,
Bangalore
 Tractors and Farm
Equipment Ltd,
Engineering Plastics
153 2012
and Tool Room
Division, Maraimalai
Nagar - Chennai
Tractors and Farm
Equipment Ltd,
154 2011
Manufacturing Unit
– Sembiam
TTK LIG Ltd,
155 2003 2004 2005
Pallavaram
TTK LIG Ltd,
156 2004 2005
Pondicherry
TTK LIG Ltd,
157 2003 2004 2005
Virudhunagar
Turbo Energy Ltd,
158 2011 2013
Pulivalam
TVS Motor Co.,
159 Plant 3, Engine 2004
Components Div.
TVS Motor
160 Company, Hosur- 2007
Plant 2
TVS Motor
161 Company, Mysore 2007
Plant
162 TVS Srichakra Ltd 2003 2005
Uniproducts (India)
163 2012
Ltd
Usha Martin Ltd,
164 2001
Jamshedpur
Usha Martin Ltd,
165 2005 2008
Wire & Wire Ropes
166 Vikram Cements 1995 2001
Wheels India Ltd,
167 2010
Padi, Chennai