MANUFACTURING EXCELLENCE THROUGH TOTAL PRODUCTIVE MAINTENANCE IMPLEMENTATION IN AN INDIAN INDUSTRY: A CASE STUDY

A case study on the implementation of TPM initiatives in the engineering industry of India is presented in this paper with an aim to demonstrate the benefits gained by the company after TPM. XYZ Group of industries is operating at three locations in NCR of India and implemented TPM Phase -I and TPM Phase –II successfully in the recent past. The study gives an understanding of the use of TPM and exhibits that TPM is one of the most powerful and efficient business practices to achieve manufacturing excellence. The OEE increased from 46% to 73.1% in TPM Phase-I and 73.1% to 85.5% TPM Phase-II respectively. A number of customer complaints reduced from 150 to zero, production cost decreased by 12% and inventory cost comes down by 35% after the completion of TPM Phase-II. The significant improvements in the TPM effectiveness indicators (PQCDSM) after implementing TPM Phase -I and TPM Phase -II proved that the Advance TPM implementation truly helped the industry in achieving high productivity, excellent quality, lowering manufacturing cost and improved delivery rate.