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TOTAL PRODUCTIVE MAINTENANCE (TPM)- Project Proposal Total Productive Maintenance (TPM) is productive maintenance carried out by all

employees through small group activities. TPM is equipment maintenance performed on a company wide basis. TPM IS CHARACTERISED BY ZERO TARGETS ZERO LOSSES ZERO BREAKDOWNS ZERO DEFECTS ZERO ACCIDENTS ZERO POLLUTION TPM EMPHASISES ON PREVENTION ABOVE ALL BASED ON THE FOLLOWING THREE PRINCIPLES 1. MAINTENANCE OF NORMAL OPERATING CONDITIONS 2. EARLY DISCOVERY OF ABNORMALITIES 3. PROMPT RESPONSE Stage 1: Breakdown Maintenance Stage 2: Preventive Maintenance Stage 3: Productive Maintenance Stage 4: TPM

1. TPM aims to maximize equipment effectiveness (overall equipment effectiveness). 2. TPM establishes a thorough system of PM for the equipment's entire life span. 3. Both operation and maintenance departments implement TPM. 4. TPM involves every single employee, from top management to workers.

5. TPM is based on the promotion of PM through motivation management: autonomous small group activities. The word "total" in "total productive maintenance" has three meanings 1. Total effectiveness 2. Total maintenance system 3. Total participation of all employees Nine Essentials of TPM 1. Self maintained work place 2. Elimination of the 6 big losses 3. Zero Breakdowns 4. Zero Defects 5. Optimal life and availability of tools 6. Self-improvement 7. Short production-development time and low machine life cost 8. Productivity in indirect departments 9. Zero Accidents Eight Pillars of TPM 1. Autonomous Maintenance 2. Continuous Improvement 3. Planned Maintenance 4. Quality Maintenance 5. Materials planning, design and equipment control 6. Education & Training 7. Office TPM 8. Safety, Hygiene and Environment Control.

IMPLEMENTATION Implementation of the concept on a trail basis in Coal Mill may be done with a stipulated action plan with the support of the top management. Requirements Manpower One operator, one mazdoor, one labour supply for creating the implementation team with Mr. Siju D and K K Abbas exclusively for the task. Office space Two computers with printer Management support As and when needed with co-operation of related departments ACTION PLAN 15 days preparation time including a visit to manufacturing industry where TPM has implemented successfully. 15 days time for office setup team building and data collection 3 months time for implementation in a given area like coal mill OUTCOME 1. TPM aims to maximize equipment effectiveness (overall equipment effectiveness). 2. TPM establishes a thorough system of PM for the equipment's entire life span. 3. Both operation and maintenance departments implement TPM. 4. TPM involves every single employee, from top management to workers. 5. TPM is based on the promotion of PM through motivation management: autonomous small group activities.