Total Productive Maintenance to Improve Overall Equipment Effectiveness
intoday‟s industrial scenario huge losses/wastage occur on the manufacturing shop floor. This waste is due to operators, maintenance personnel, process, tooling problems and non-availability of components in time etc. Other forms of waste include idle machines, idle manpower, break down the machine, rejected parts etc. are all examples of waste. The quality related waste is of significant importance as they matter the company in terms of time, material and the hard-earned reputation of the company. There are also other invisible wastes like operating the machines below the rated speed, setup-up loss, the breakdown of the machines and bottlenecks in the process. Zero oriented concepts such as zero tolerance for waste, defects, break down and zero accidents are becoming a pre-requisite in the manufacturing and assembly industry. In this situation, a revolutionary concept of Total Productive Maintenance (TPM) has been adopted in many industries across the world to address the above-said problem. The goal of any TPM program is to improve productivity and quality along with increased employee morale and job satisfaction. Earlier preventive maintenance was considered as a nonvalue-adding process, but now it is an essential requirement for the longer life cycle of machines in an industry. TPM is an innovative approach to maintenance that optimizes equipment effectiveness, eliminates breakdowns, and promotes autonomous operator maintenance through day-to-day activities involving the total workforce. The study reveals that the TPM elementstop management leadership, planned maintenance management, focused improvement, autonomous maintenance and education and training have a significant contribution towards manufacturing performance such as lower cost, higher quality, strong delivery and increased productivity. TPM is an innovative Jap a nese concept. The origin of TPM can be traced back to 1951 when preventive maintenance was introduced in Japan. However, the concept of pre
