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Business Excellence with STSTSTST
Enabling the Organization to overcome the todays’ competition, with the continuous
improvement philosophy of TPM.
TPM philosophy support the ordinary organization to become best in competition.
TPM makes Organization not only most profitable in competition but also better in
Quality, Safety , Motivation and interruption free supplies to customers.
Education :-Post Graduate Diploma in Plastic Processing Technology
MBA from MDI Gurgaon, (Operations and Finance)
Professional Career :-20 Years experience in Manufacturing in various
functions in automotive industry specialization in
plastic industry.
Award & Recognitions :-JIPM-TPM Consistency Award of Lumax one Plant
-JIPM-TPM Excellence award of Category-A , Lumax
two Plants
-JIPM-TPM Excellence award of Category-B Lumax
one Plant
-Bajaj TPM Award, two Lumax Plants
-Bajaj TPM Excellence Award, One Lumax Plant
-Bajaj Quality Bronze, Silver, Gold and Gold
Consistency Award
-ACMA Manufacturing Excellence Award Silver
-ACMA Q&P Gold Award
-Highest purple Quality Rating from Mahindra
-Tata motors world class award level-2
Sandeep Tyagi
Sr. Counselor,
A-34,Balaji Apptt.
Laal Dant, Talli Bamori,
Haldwani, Uttarakhand,263139
Contact Detail : Mob.-
9997192110
e- mail :
Web site : www.tpmservices.in
Bharat Consultancy Services
The proposal is to implement Total Productive Maintenance in your organization which consists
of class room training and shop-floor technical guidance.
The class room training is to advance the user awareness regarding the advanced TPM
Concepts.
The shop-floor guidance is to implement the TPM concepts in the manufacturing to make more
profitable, efficient and flexible organization.
Post liberalization in 1991 ,
Most of the big Industrial units
did close the gap in Technology
/ Quality /Productivity / Price
wrt global bench marks to a
large extent , But The small &
medium players were left out in
modernization and continued
depends on low cost man
power.
In Consumer goods , most of
the Indian brands got swept
away.
Overall , almost all players
concentrated on just meeting
the growing demand. Not much
long term thought process.
Most player were happy about the overall economic growth , the gradual
domination of foreign players/foreign technology/ foreign brands and increasing
share of low cost Chinese imports , creating challenge to the Manufacturing sector in
India.
While everyone was busy with domestic market , the need for Indian Manufacturing
sector to maintain a fair share in global market , was neglected.
The following is a snapshot of the present set of problems
• General economic slow down, surplus capacity in certain sectors which has a
cascading effect on Big / medium/small industries
• SMEs ( small & medium enterprises) are not modernised and productivity is slow.
• Slow adoption of new technologies ( 3D Printing , composites, new tooling etc).
• Process & Quality management is below par . On time delivery record is also low.
• Financing costs are very high . This impacts global competitiveness in
manufacturing.
• Infrastructure for domestic sourcing /imports is inadequate
• The eco system for Design /Tech development / innovation / Productivity
improvement is not conducive.
• Most of the entrepreneurs looking for short term returns rather long term thinking.
Opportunity and Challenges in Indian Economic Environment
Bharat Consultancy Services
STSTSTST
If India continues on its present growth
course, it could have a US$5.6 trillion
economy in 20 years. To create a US$10
trillion economy, India will need to
accelerate its growth to 9% CGAR over the
next 20 years.
• Low profit margins
• Frequent defects and breakdown brand deterioration.
• Un-happy customer leading to business risk.
• The cost of manufacturing is continuously increasing.
• The development time and cost is very high.
• Very less technological improvements.
• High level of inventories leading to blockage of funds.
• Low return of Investment.
• Higher attrition rate.
• Low improvement suggestions and Kaizens.
• Higher in-house rejections ,defects and re-work.
• No standard manufacturing process.
• Less learning opportunity to the employees.
• Resistance to change.
• Frequent breakdowns in machines.
• Un-Healthy and un-ergonomic environment in the plant.
• Frequent human accidents in the plant.
• Un-even productivity level.
• Frequent m/cs stoppage because of weak planning process in the plant.
• Less capacity utilization.
Inconsistency in
meeting the legal
compliances.
Human safety , health
and Environmental
compliances and other
statutory compliances.
Irregularity in re-payment of loans
and advances.
Organizational Challenges
• Higher product pricing.
• Frequent Quality
complaints.
• Higher field failures.
• Inconsistency in delivery.
• Quality and delivery issues
during new product
development.
• Less flexible to VA-VE
• Repeated defects and
inconsistency
• Un-systematic
• High development lead
time and cost.
STSTSTST
Strategic Business Planning Long
Term
Values
World Class Award
Advance TPM Special Award
TPM Special Award
TPM Consistency Award
TPM Excellence Award
� Supporting
Organization for
developing Vision &
Mission & Values.
� Supporting
organization to
developing the
strategy aligning
with the Vision of
the company.
�Guiding the Organization to
achieve JIPM-TPM award.
�Guiding the Organization for
sustaining the TPM
improvements.
� Supporting the organization up-to
World class Award from JIPM.
Supporting an Organization to become a respectable organization.
Developing Organization best in class as “Good to Great “ and finally the
Organization which is ” Built to Last”.
STSTSTST
Bharat Consultancy Services
� Supporting organization for developing short term and long term Business plans/
strategies.
� Support in developing the review mechanism for achieving the business targets
in TPM way.
1
2
3
4
5
Implementation Mechanism
Reduce! the Cost
Reduce operation-related losses, line
organization-related losses and
production/energy resources-related
losses
Improve! the Process
Optimize whole production processes
by enhancing coordination with
related sections from a perspective of
production processes, while
continuing with the activities from
Part I
Develop! the Enterprise
Optimize whole business processes
while continuing with the activities
from Part I and Part II
Improvement of the
cultures of production
sites
Optimization of whole
production processes
Optimization of whole
business processes
TPMPart I
Groundwork
TPMPart II
Structuring(High Productivity)
TPMPart III
Overall improvement
of plants/companies(High Value)
Improve Corporate Values
Part l (production costs) Part ll (product costs) Part lll (total cash flow)
Manufacturing processProduction site Business processBusiness processBusiness processBusiness process
Pro
du
ction
site
Op
timize
d to
tal b
usin
ess p
roce
ss
Op
timiza
tion
of to
tal m
an
ufa
cturin
g p
roce
ss
Losses on machine
Operation, Losses on
Organization for operation
Losses on material and
energy
Productivity of
Production site
Collaboration with
Production Div.Sales Div, e.g) Opportunity lost,
Product inventory loss
Development&Design Div, e.g)
Achievement loss to target cost
On new product
Sourcing Div,e.g)Excess parts&
Material,target cost loss to buy
Efficiency of
Company
Management
Sales Div,e.g)
Operating ratio loss
Research Div, e.g)
Marketing share
Of new products
Part ll is optimize total
Manufacturing process with
related division by
continuing
Activity since part l .
Productivity of
manufacturing
Improvement Milestones
Bharat Consultancy Services
STSTSTST
Tactical Level Planning
Resource Planning
Mid
Term
KK
JH
PM
QM
DM
ET
OTPM
SHE
TPM
5S – BASE OF TPM
Top
Management
Middle
Management
Lower management
and
Associates
�Guiding for lean and balanced
organization structure for
supporting the TPM in the
plant.
� Establishing the Pillar and Circle
structure in the plant.
� TPM related Trainings at all
levels of organization.
�Guiding for coordination among
all levels of organization for
getting synergy of all levels.
� Establishing 8 Pillar Structure in
the plant.
�Guiding in developing the KMI in
P,Q,C,D,S,M way at Plant level.
�Guiding in developing the KPI at
Pillar/Departmental level.
�Guiding in developing KAI at
Circle level.
�Guiding in developing the
review mechanism at all level in
TPM way.
�Guiding in developing the
Kaizen and Suggestion
environment in the plant.
�Guiding for developing Daily
Work Management in the Plant.
Creating synergy in the Organization towards Improvement
STSTSTST
Bharat Consultancy Services
Top
Management
Middle
Management
Lower management
and
Associates
Implementation Mechanism Cont….
Bharat Consultancy Services
Imp
lem
en
tati
on
Me
cha
nis
m C
on
t….
STSTSTST
Operational level
Pillar
Heads
Short
Term
�Guiding in developing 5 S
mechanism in the Plant.
� Training to all employees for
understanding and maintaining the
highest level of 5S.
� Establishing the 5S standards acrossthe plant.
�Guiding for developing the PDCAthinking in manufacturing.
�Guiding for developing Why-Whybase analysis thinking.
Steering
Committee
Pillar
Heads
Circle
Heads
Circle
Heads
TPM
Coordination
Cell
Circle
Heads
Deptt.
Deptt.
Deptt.
Deptt.
Deptt.
�Guiding in developing TPM Organization
structure with in the Plant Organization
Structure.
STSTSTST
Bharat Consultancy Services
Implementation Mechanism Cont….
Improvement
in all flows of
manufacturing
Annual Plan From
Customer Corporate
Customer Local PPC
( Monthly Schedule )
Corporate capacity
Planning
Assembly
Supplier
StoreManufact
uring -1
Manufactur
ing-2Dispatch
Monthly & Daily scheduling & Planning
Information Flow
Material Flow
Money Flow
Plant PPC
Corporate Account
Improvement in Planning System
Purchase
Annual
Budges
Capacity Plans
1 Year 1 Year 6 months 1 Year
Step 0 5S implementation
1. Top Management’s
declaration to introduce
TPM.
2. Introduction Training
3. TPM Organization
4. Target Setting
5. Master Plan
6. TPM Kick Off
Step 1-7
Preparation Implementation Expansion
7-(3) Planned Maintenance
7-(2) Autonomous Maintenance
7- (1) Focused Improvement /OEE Improvement
7-(4) Training and Skill Development
8-(5) Initial Phase Management
9-(6) Quality Management
10-(7) Office TPM
11-(8) Safety &
Environment
Step -7 Step -8-9 Step -10-11
12 –Application of TPM
TP
M A
WA
RD
TPM Implementation Timing Plan
Customer
Bharat Consultancy Services
STSTSTST
Increase in Stakeholders Value
Increase in the
Director
Confidence
Employees Customers Government SupplierShareholder
Value
Local
Community
(CSR)
Consistent
and good
quality
product
supply
Able to
protect
Environment
Increase in
Share price
Increase in
Profitability
consistently
Lowest
attrition
rates
No
Hazardous
waste
Better
communication
/planning
system
Getting VA-
VE Proposals
Meeting the
compliances
Increase in
business
volume
consistently
Clean, safe ,
participative
Working
Environment
Having on
time
payment
system
Increase in
customer
response
Increase in
business
portfolio
Ease in
doing work
Increase in
Customer
Satisfaction
Index
Flaw less
manufacturing
Knowledge
upgradation
CSR
activities
Bharat Consultancy Services
STSTSTST
ABI Showatech (India) Ltd, Brake Master Cylinder
Manufacturing Plant in Pulivalam , Sholinghur
Aditya Cements
Apcotex Industries Ltd Taloja Plant
AQUA Group, Aquapump Industries, Aquasub Engineering
(Unit I, II, III, IV)
Aradhana Soft Drinks Company, Panipat Plant
Asahi India Glass Ltd, Auto Glass Division, Bawal Plant
Badve Engineering Ltd., Polymer Plant
Bajaj Auto Ltd, Akurdi Plant, Pune
Bajaj Auto Ltd, Chakan
Bajaj Auto Ltd, Commercial Vehicle Division (CVD), Waluj
Plant, Aurangabad
Bharat Seats Ltd, Gurgaon Plant
Birla Tyres, Balasore
Brakes India Ltd - Foundry Division, Sholinghur
Brakes India Ltd, Brake Division, Sholinghur
Brakes India Ltd, Nanjangud
Brakes India Ltd, Padi Plant
Brakes India Ltd, Polambakkam
Chennai Petroleum Corporation Ltd, Cauvery Basin
Refinery
Chennai Petroleum Corporation Ltd, Manali Refinery
Dattatreya Textile Pvt Ltd
Delphi-TVS Diesel Systems Ltd
Electrosteel Castings Ltd, Khardah Works, Kolkata
List of JIPM Certified Indian Companies
Bajaj Auto Ltd, Motorcycle Division (MCD), Waluj Plant,
Aurangabad
Bajaj Auto Ltd, Pantnagar Plant
Balasore Alloys Ltd
Emami Paper Mills, Balasore
Endurance Technologies Pvt Ltd, (Clutch Div - Waluj), High
Technology Transmission Systems (I) Pvt Ltd
Endurance Technologies Pvt Ltd, B-2, Casting Div.,
Aurangabad
Endurance Technologies Pvt Ltd, Braking Division
Endurance Technologies Pvt. Ltd (Suspension Division)
Plot No. K-228/229 & E-92/93
Endurance Technologies Pvt. Ltd L6/3 - Casting Division
Fenner (India) Ltd, Hyderabad Plant - 1
Fenner (India) Ltd, Madurai Plant - 1
Galaxy Surfactants Ltd, Taloja Plants
Galaxy Surfactants Ltd, Tarapur Plants
Godrej & Boyce Mf. Co. Ltd., Godrej Precision Systems
Godrej Consumer Products Ltd, Malanpur
Gontermann-Peipers (India) Ltd
Hero MotoCorp Ltd, Dharuhera Plant
Hero MotoCorp Ltd, Gurgaon Plant
Hero MotoCorp Ltd, Haridwar Plant
Hi Tech Carbon Ltd, Gummidipoondi
Hi Tech Carbon Ltd, Renukoot
Hindustan Coca-Cola Beverages Pvt Ltd., Moula Ali Plant
Hindustan Coca-Cola Beverages Pvt Ltd., Srikalahasthi
Hindustan Lever Ltd, Beverages Factory, Pondicherry
List of JIPM Certified Indian Companies Cont….
Exide Industries Ltd SF Division, Taloja Plant
Exide Industries Ltd, Chinchwad
Exide Industries Ltd, Haldia Factory
Exide Industries Ltd, Hosur Plant
Hindustan Lever Ltd, Chindwara
Hindustan Lever Ltd, Chiplun Plant
Hindustan Lever Ltd, Daman Detergents
Hindustan Lever Ltd, Hosur
Hindustan Unilever Ltd, Haldia Detergents Factory
Hindustan Unilever Ltd, Khamgaon
Hindustan Unilever Ltd, Nashik Factory
Hindustan Unilever Ltd, Pune Tea Exports Factory
Hi-Tech Gears Ltd (Group), Hi-Tech Gears Ltd and Getrag
Hi-Tech Gears (India) Pvt Ltd (Bhiwadi), Hi-Tech Gears Ltd
(Manesar)
Hospet Steels Ltd
Indian Oil Corporation Ltd (Assam Oil Division), Digboi
Indian Oil Corporation Ltd, Barauni Refinery
Indian Oil Corporation Ltd, Bongaigaon Refinery
Indian Oil Corporation Ltd, Guwahati Refinery
Indian Oil Corporation Ltd, Haldia Refinery
Indian Oil Corporation Ltd, Panipat Refinery
Indo Gulf Fertilizer Ltd
Ispat Industries Ltd, Dolvi
Ispat Industries Ltd, Kalmeshwar
J K Paper Ltd, Central Pulp Mills
J K Paper Ltd, J K Paper Mills, Jaykaypur
Hindustan Lever Ltd, HPC DIV-Detergents Factory,
Pondicherry
Hindustan Lever Ltd, Kalwa Factory
Hindustan Lever Ltd, Kandla Factory
Hindustan Lever Ltd, Khaliabad Beverages Factory
Hindustan Lever Ltd, Kidderpore Beverages Factory
Hindustan Lever Ltd, Mangalore
Hindustan Lever Ltd, Mysore Beverages Factory
Hindustan Lever Ltd, Orai
Hindustan Lever Ltd, Personal Products, Dadra
Hindustan Lever Ltd, Personal Products, Pondicherry
Hindustan Lever Ltd, Rajpura
Hindustan Lever Ltd, Silvasa Beverages
Hindustan Lever Ltd, Silvasa Detergents
Hindustan Lever Ltd, Sumerpur
Hindustan Lever Ltd, Tatapuram Factory
Hindustan Lever Ltd, Toilet Soap Factory, Goa
Hindustan Lever Ltd, Western Regional Office
Hindustan Lever Ltd, Yavatmal
Hindustan Motors Ltd (AVTEC Ltd, Power Plant,Pithampur)
Jamshedpur Utilities and Services Company Ltd
Jindal Stainless Ltd, Hisar
JK Tyre & Industries Ltd, Banmore Tyre Plant
JK Tyre & Industries Ltd, Kankroli Tyre Plant
JK Tyre & Industries Ltd, Vikrant Tyre Plant, Mysore
LAP-Ross Engineering Ltd
Light Alloy Products Ltd
Lumax DK Auto Industries Ltd, Pantnagar
Mahindra & Mahindra Ltd (Auto Div.), Mumbai
Mahindra & Mahindra Ltd, Farm Division, Mumbai
Mahindra & Mahindra Ltd, Farm Division, Nagpur
Mahindra & Mahindra Ltd, Farm Division, Rudrapur
Mahindra & Mahindra Ltd, Farm Equipment Sector, Swaraj
Division - Plant 1
Mahindra & Mahindra Ltd, Farm Equipment Sector, Swaraj
Division - Plant 2
Minda Industries Ltd Switch Division, Pune
MRF Ltd - Arkonam Unit
MRF Ltd - Goa Unit
MRF Ltd - Kottayam Unit
Mukand Ltd, Kalwe Steel Plant
Mukand Ltd, MBD
Munjal Showa Ltd, Gurgaon Plant
Munjal Showa Ltd, Manesar Plant
National Engineering Industries Ltd, Jaipur
National Engineering Industries Ltd, Newai Plant
Orient Cement (Props: Orient Paper & Industries Ltd),
Orient Cement, Clinker Grinding Unit (CGU)
Orient Cements, Devapur Cement Works
PepsiCo India Holdings Private Ltd (Fritolay Division),
Channo Plant
PepsiCo India Holdings Private Ltd, Frito Lay Division,
Kolkata Plant
PepsiCo India Holdings Pvt. Ltd, Pune Foods Plant
QH Talbros Ltd, IMT Manesar
List of JIPM Certified Indian Companies Cont. ……
Raychem RPG (P) Ltd International Business Division, Vasai
Showa Engineering Ltd, Melvenkatapuram
Shriram Pistons & Rings Ltd
Sona BLW Precision Forgings Ltd, Gurgaon Plant
Sona BLW Precision Forgings Ltd, Pune Plant
Sona Koyo Steering Systems Ltd, Gurgaon
Sona Somic Lemforder Components Ltd, Gurgaon Plant
Sundaram Clayton Ltd, Brakes Division, Plant 2
Sundaram Clayton Ltd., Die Casting Div., Hosur Plant
Sundaram Industries Ltd - Rubber Factory
Sundaram Textiles Ltd, Nanguneri Unit
Sundaram-Clayton Ltd, Padi Plant
Sundram Fasteners Ltd, Hosur
Sundram Fasteners Ltd, Krishnapuram Plant
Sundram Fasteners Ltd, Padi
Sundram Fasteners Ltd, Pondicherry
Tanfac Industries Ltd
Tata Cummins Ltd
Tata Metaliks, Kharagpur
Tata Sponge Iron Ltd, Joda
TATA Steel Processing and Distribution Ltd, HR Plant & CR
Plant, Jamshedpur
Telco Construction Equipment Co. Ltd (TELCON), Dharwad
Telco Construction Equipment Co. Ltd (TELCON),
Jamshedpur
Tetra Pak India Private Ltd, Tetra Pak, Pune
The Supreme Industries Ltd, Pondicherry Plant
The Tata Iron & Steel Co Ltd, Bearings Div.
The Tata Iron & Steel Co Ltd, Hot Strip Mill
The Tata Iron & Steel Co Ltd, Precision Tube Mill, Tube
Div.
The Tata Iron & Steel Co Ltd, Wire Rod Mill
The Tinplate Co. of India Ltd, Golmuri Works
Titan TimeProducts Ltd
Tractors and Farm Equipment Ltd, Engineering Plastics
and Tool Room Division, DBR, Bangalore
Tractors and Farm Equipment Ltd, Engineering Plastics
and Tool Room Division, Maraimalai Nagar - Chennai
Tractors and Farm Equipment Ltd, Manufacturing Unit -
Sembiam
TTK LIG Ltd, Pallavaram
TTK LIG Ltd, Pondicherry
TTK LIG Ltd, Virudhunagar
Turbo Energy Ltd, Pulivalam
TVS Motor Co., Plant 3, Engine Components Div.
TVS Motor Company, Hosur-Plant 2
TVS Motor Company, Mysore Plant
TVS Srichakra Ltd
Uniproducts (India) Ltd
Usha Martin Ltd, Jamshedpur
Usha Martin Ltd, Wire & Wire Ropes
Vikram Cements
Wheels India Ltd, Padi, Chennai
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