TPM at Toyota Kirloskar Auto Parts Private Limited

Total Productive Maintenance (TPM) is a unique Japanese philosophy, which was developed based on productive maintenance concepts and methodologies. This concept was first introduced by M/s Nippon Denso Company Ltd., of Japan, a supplier of M/s Toyota Motor Company, Japan in 1971. TPM is an innovative approach to maintenance that optimizes equipment effectiveness, eliminates breakdowns, and promotes autonomous maintenance by operators through day-to-day activities involving total workforce.

The TPM awards were established in 1969 by the Japan Institute of Plant Maintenance (JIPM) in Japan to strengthen the improvement of enterprise constitutions and contribute to the devel­opment of industry, by promoting the modernization of plant maintenance and the develop­ment of plant maintenance technologies. The main purpose of the TPM award is to encourage development of the manufacturing industries and factories that displayed remarkable achieve­ment in plant maintenance. TPM awards are given to companies inside and outside Japan.

Toyota Kirloskar Auto Parts Private Limited (TKAP), established in 2001, is an auto parts manufacturing company based at Bidadi near Bangalore, India. It is a joint venture amongst Toyota Motor Corporation, Japan; Toyota Industries Corporation, Japan, and Kirloskar Sys­tems Limited, India. TKAP manufactures axles and shafts, and transmissions and engines and supplies them to Toyota companies globally and locally. TKAP received the TPM excel­lence category award from JIPM for maintaining quality, safety, secure, and reliable produc­tion, and for maintenance activities.

“Intrinsic is the belief that quality does not happen by accident, it must be planned,”

Peter F, Drucker

Upon completion of this chapter, you will be able to:

  1. Explain reliability
  2. Understand failure mode and effect analysis
  3. Understand total productive maintenance (TPM)
  4. Identify the pillars of TPM
  5. Find out the overall equipment effectiveness
  6. Explain the various steps in the introduction of TPM

Source: Poornima M. Charantimath (2017), Total Quality Management, Pearson; 3rd edition.

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