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TPM (Total Productivity Maintenance)
What is Total Productivity Maintenance (TPM)?

“It can be considered as the medical science of machines.”
Total Productivity Maintenance (TPM) is a maintenance program which involves a newly defined concept for maintaining plants and equipments.The goal of the TPM program is to markedly increase production while, at the same time, increasing employee morale and job satisfaction.TPM brings maintenance into focus as a necessary and vitally important part of the business.

SCOPE OF WORK

  • Reports/Charts
  • Trend of Production
  • Trend chart of: a) OEE , b) ROA, c) ROP, d) ROQ
  • Trend of Delays
  • Trend of Overall Plant Efficiency
  • Production Cost Efficiency
  • Production Lead Time Efficiency
  • Non-defective Rate
  • Heat and Motive Power efficiency
  • Labour Productivity
  • Lead Time Efficiency
  • All type of losses Trend
  • MTTR / MTBF
  • Trend of Efficiency
  • Loss Pareto Analysis
  • Kaizen Management
  • Provisions of Why Why Analysis on all levels
  • PP Material Physical Phenomena Tread of Down time
  • Tag Matrices Abnormality
  • Trend of CLITA Activity
  • Operator / Machine efficiency
  • Mold wise Efficiency
  • Officer wise Efficiency
  • Trend of Rejection
  • Trend of Accidents
  • Training
  • GroupWise yield
  • Operator History
  • Machine History
  • Capturing of Tool Life
  • Trend of Mold Change
  • Trend of Expenditures
  • QA Matrix 3M Analysis
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    Application Features:

  • Improve the decision making process by providing the required data anytime and anywhere.
  • Company – multi unit (factory) configuration can be done for company wide software usage with single server installation.
  • Flexibly configure various factory configurations of the company.
  • Map factory wide equipment structure for efficient management of data processing and its analysis as required for TPM activities.
  • User rights management at unit and company level for managing software feature usage.
  • Management KPI Dashboard which helps to measure TPM effectiveness. Dashboard can be customized at company, unit, department and/or user levels.
  • Carry out Why-Why analysis process across TPM pillars.
  • Kaizen Management has been provided as a separate feature to keep track of all the Kaizens created and also their horizontal deployments.
  • Loss structure which forms the base for analysis is completely flexible and configurable.
  • This solution makes the complex calculations for ROA, ROP, ROQ and OEE/OPE so easy.
  • Enter the losses incurred and all the above values can be obtained just by clicking a button.
  • Provides facility to create QA Matrix, 3M Analysis.
  • Benchmark and Target processing on various indexes.
  • Provides an option to Export Data to Excel file.
  • Trends generated based on equipments and time duration (frequency), which also to drill down to the root level.
  • Provides an extensive Reporting system which makes analysis very easy.
  • Just to name a few of the complex reports and trends
    1. a. Loss Physical Phenomena Matrix
      b. MTTR/MTBF
      c. Loss Pareto Analysis
      d. Performance Efficiency Trend
      e. Kaizen Management
      f. Production Details
      g. Maintenance Expenditure wise Trend
      h. Track Machine history, which includes following details like :
      Production, Downtime, Breakdown, Abnormalities,Maintenance activities, Spares, Kaizens.
  • Provides One Click Backup: Backup of the data can be taken anytime from any location where the web application is accessible.
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    Clients:

  • Tata Batteries
  • Luminous