In today’s industrial scenario huge losses/wastage occur in the manufacturing shop floor and foundry industries. This waste is due to operators, maintenance personal, process, tooling problems and non-availability of components in time etc. Other forms of waste includes idle machines, idle manpower, break down machine, rejected parts etc. are all examples of waste. The quality related waste are 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, startup loss, break down of the machines and bottle necks in 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 TPM has been adopted in many industries across the world to address the above said problems.
TPM stands for Total Productive Maintenance, or productive maintenance with total participation. First developed in Japan, TPM is a team-based preventive and productive maintenance, both abbreviated as ‘PM’, and involves every level and every function in the organisation, from top executives to the production floor operators. Preventive Maintenance can be thought of as a kind of physical check-up and preventive medicine for equipment. Just as human life expectancy has been expanded by the progress in preventive medicine to prevent human suffering from disease, the plant equipment service life can be prolonged by preventing equipment failure (disease) beforehand. In 1971, Nippon Denso Co. introduced and successfully implemented a program called ‘Total Productive Maintenance’ in Japan. They won the PM Excellence Plan Award for their efforts. This was the beginning of TPM in Japan. It got popular rapidly in the U.S.