Total Productive Maintenance (TPM) and Gemba Kaizen

Ispat Industries Limited (IIL) has adopted the Total Productive Maintenance (TPM) and Gemba Kaizen approaches at its Dolvi plant to function as drivers to quality and productivity enhancement. To date, the implementation of TPM has enabled IIL to achieve savings of over Rs 4.4 crore.

TPM
The TPM philosophy comprises a systematic methodology that aims to change the organisation by changing the thinking style of people within the organisation. It is a philosophy of prevention that advocates participation by all, and envisages an organisation that is transformed into a learning workplace where people derive satisfaction through daily improvement.

This approach focuses on developing a strong and profitable company constitution by completely eliminating defects, customer complaints, breakdowns and accidents within an organisation. For this purpose, it suggests methods for loss identification, loss quantification and loss elimination. And, thereafter for sustaining the improved condition and steadily making further continuous improvements.

IIL has enjoyed the following gains through the adoption of TPM:
· Increased productivity
· Improved product quality
· Reduced manufacturing cost
· On time delivery, always
· Improved work environment
· Motivated employees
· Improved brand image
· Delighted customers

Gemba Kaizen
Gemba Kaizen involves measures to reduce wastage within an organisation. This involves detecting waste, diagnosing its root cause and developing the necessary countermeasures. The next step is to implement the countermeasures and eliminate the root cause. Thereafter, the improved operating practices are standardised and new projects are targeted for implementation of Gemba Kaizen.

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