The document presents two case studies on implementing Total Productive Maintenance (TPM) at different companies. In the first case study, TPM was implemented at a small-scale agricultural equipment manufacturer which improved organization of assembly lines, increased worker skills, upgraded equipment, and increased overall equipment effectiveness (OEE) from 60% to 82%. The second case study implemented TPM at a plastic bottle manufacturer which standardized storage and production processes, improved layouts, implemented preventative maintenance, enhanced working conditions, and increased OEE from 75% to 83%. Both case studies found that TPM principles helped increase productivity, quality rates, and overall equipment performance.

1. CAREER POINT UNIVERSITY, KOTA
MAJOR ASSIGNMENT OF OPC
CASE STUDY OF TPM
PRESENTED BY :-
ASHOK KUMAR SINGH
UID – K10798
BRANCH – MECHANICAL
COURSE – B.TECH
YEAR/SEM – 3RD /6TH
SUBMITTED TO :-
MR. BHUPENDRA GAHLOT
ASSISTANT PROFESSOR
MECHANICAL DEPTT.

2. CONTENTS
• INTRODUCTION
• PILLARS OF TPM
• OBJECTIVES
• BENEFITS
• CASE STUDY

3. INTRODUCTION
• It is an innovative Japanese technique
• It is the major part of the industry to improve the
effectiveness of productivity
• It is applicable to every industry
• Careful & intentionally working by employees in the
industry
• Complete solution of all industry to increase the
productivity

4. PILLARS OF TPM
• Initial Flow Control Activity
• Focused improvement
• Autonomous Maintenance
• Quality Maintenance
• Planned Maintenance
• Environment, Health and Safety
• Admin TPM
• Education and Training

5. OBJECTIVE OF TPM
• Involve people in all level of organisation
• Achieve zero defect and zero accident
• Increase production
• Job satisfaction

6. BENEFITS OF TPM
• Increase OPE
• Rectify customer complaints
• Follow pollution control measures
• Share knowledge and experience
• Achieve goal by working as a team
• High confidence level among employees

7. CASE STUDY
[Gill Agricultural Implements Private Limited]
• It is a small scale industry
• Located in Punjab
• Main products are – multi crop thresher, tractor mounted
harvester, tractor mounted spray pump,self propelled
harvester
• We have done our case study on multi crop thresher
assembly line
• Daily production is 10 machines/day
• Work is divided for assembly of multi crop thresher on 12
stations

8. PROCESS FLOW DIAGRAM

9. SUGGESTION AND IMPLEMTATION OF TPM
• At time of Assembly of threshers there is no sequence of work and these
cause to waste of time. After gives the suggestions Assembly of threshers
working in line and this cause reduce the time of operation
• In these Industry workers has not well skilled in every work. Employee do
only one type of work in Industry. This situation create problem at time of
working. To solve this problem we create the skilled matrix generation
method to improved skill of workers in Industry
• Before implementation TPM industry used shearing machine (manually
operated), that consume lot of time and wastage of raw material. After
suggestion industry has purchased plasma cutting CNC machine that has
increase the quality and quantity of work and less man power required
• In the duration of lunch time (60 min) maintenance personnel must do
preventive maintenance of the plant

12. Scrap loss before TPM Scrap loss after TPM

13. CONCLUSION
• We see that OEE value of this Industry is 60% approximately, this
value is not good for industry and this cause to less profit .
• We found some type of problems and weakness of workers or industry
at time of working. So we think that there is need of TPM
Implementation in this Industry and after it we give some suggestion
by the help of study TPM Pillars.
• Then we got the result, the working environment of this industry is
improved and the OEE of Industry rise to 82%
• After the result clears that by the help of TPM, industry improved its
OEE. IT directs help to increase productivity and profit of the
industry.

14. CASE STUDY
[M/S. SKYPET POLYMER]
• Produces plastic bottles and caps
• Production takes place in two units which are 9 km
apart
• In unit A , two injection moulding machine are present
and are used to make bottle caps.
• In unit B, three blow moulding machines are present
where assembly with the caps , packed and dispatched
are done

15. PROCESSES CARRIED OUT IN THE INDUSTRY

16. SUGGESTION AND IMPLEMENTATION OF TPM
• There is no sequence of work and these causes to Waste of time. After
gives the suggestions Assembly of machines working in line and this
cause reduce the time of operation.
• In the duration of lunch time (60 min) maintenance personnel must do
preventive maintenance of the plant.
• Before implementation of TPM there is no proper working condition of
workers. And after implementation TPM improved the working
condition of workers by gives healthy food and purify ground water.
• At the initial phase of our study many employees consider it is an
additional or burden but after implementation they feel that it is a win
situation for industry and employees.

17. OEE CALCULATION BEFORE TPM OEE CALCULATION AFTER TPM

19. CONCLUSION
• By implementing the principles of lean manufacturing in the various processes,
standardization was achieved as well as improved productivity in a few areas.
The management was satisfied with the results the changes were able to
produce.
• The following goals were accomplished:
• The storage space in Unit A was standardized.
• The productivity in Unit B improved after changing the layout. This was in
the areas of packing and material handling.
• The inventory could be maintained better owing to a simple inventory
management system.
• The OEE value was found to be only 75% approximately, now it has improved
to 83%.
• A better quality rate has been achieved as a result of implementing TPM.