Filtering out waste with TPM

Chennai: Like all other TVS GROUP companies, the quality bug smote Delphi TVS Diesel Systems Limited too.

Faced with 370 machine breakdowns in a month, the company took to total production maintenance (TPM) for its plant improvement in 1999 under the mentorship of Japanese productivity expert S Yamaguchi.

The Japanese guru first addressed the top management to get its commitment towards TPM. Later, nine managers were trained and each took responsibility care of one machine. They were 'owners' for the functioning and problems of those machines and were expected to know everything about them.

Six months later, after seeing the improvements in their machines, TPM was implemented throughout the company.

According to NC Krishnakumar, executive vice president, "TPM has benefited the company. For instance, the machine breakdowns came down to just three per month. The machine utilisation went up to 80 per cent from 60 per cent."

According to company officials, the TPM goal is to have zero-machine breakdowns, defects or accidents. Even when buying machines, the company prefers 'TPM-friendly' machines to others.