Did you know, one of the worlds renowned automotive manufacturers and suppliers has been using and implementing Total Productive Maintenance since the 1990s?
The organization has a lot of production units across the world, out of which Belgium’s production unit was the highest producing plant amongst others. The growth of the organization was the decades of efforts that the organization has put in. To improve its production, one of its production managers visited Japan to understand Japan’s local production system.
In the 1990’s the organization started to decisively implement TPM – Total Productive Maintenance methodology. The maintenance was fully integrated within the production system of the organization. The maintainability and reliability of the equipment were given more attention. As a result of their Total Productive Maintenance efforts, this organization became the first manufacturing company of Europe to achieve Total Productive Maintenance world-class award.
Total Productive Maintenance through Continuous Improvement
The same year, this organization was taken over by another organization where the acquisition required the organization to align its production system with other acquiring organization’s production system. After thorough analysis and benchmarking of a few plants, it was found that though this organization had a big lead in different manufacturing techniques but, there was one problem. The approach of this organization was not uniform across different establishments of its cars. After which the acquiring organization created its own manufacturing system which helped this organization to make the approach identical across its cars.
Based on this model, a common maintenance process was established across the organization, maintenance tools were introduced, and training was initiated. As a result, the organization started to produce, 2,50,000 cars a year along with 8,000 assets, 828 robots and on a 9.8 miles long conveyor belt. At present their technical availability is 98.7% which makes the organization a top tire performer in a world-wide car manufacturing industry.
Hence, as you can see, even the world’s leading manufacturers are reaping fruitful results with the help of Total Productive Maintenance, have you started implementing TPM in your organization yet?
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Compiled by Faber Priyal & Faber Mayuri