1. ► TPM ACTIVITY ROADMAP OF PLANT
Plant Target Setting:
1. Customer Expectation:
No.
Parameter
Bench
Mark
Target FY FY Q1 Q2 Q3 Q4 1
Supply with Zero Customer Complaints 2
On time Delivery
100% 3
Zero Field Failures 4
Reduce New Product Development Lead Time 5
Vertical Ramp with
Zero Customer Complaint
Zero In House Rejection

2. ► TPM ACTIVITY ROADMAP OF PLANT
Plant Target Setting:
2. Plant or Company Target
Area
Parameter
Bench
Mark
Target FY FY Q1 Q2 Q3 Q4 P
OEE
85%
Production/Hour
10% up
Output/Man/Shift
Breakdown Time Q
Customer Complaints
In house Rejection
Zero defect from BOP C
Variable Manufacturing Cost
5% Down
YOY
Cost Loss Elimination
Cost Reduction
Cost of Poor Quality

3. ► TPM ACTIVITY ROADMAP OF PLANT
Plant Target Setting:
2. Plant or Company Target
Area
Parameter
Bench
Mark
Target FY FY Q1 Q2 Q3 Q4 D
Delivery Adherence
100%
WIP Reduction
Supply through FG Inventory
Mfg. Lead time Reduction
Dev. Lead time Reduction S
Major Accident
Minor Accident
Occupational Health Hazards
Environment Pollution due to Process
Green Area Improvement
35%

4. ► TPM ACTIVITY ROADMAP OF PLANT
Plant Target Setting:
2. Plant or Company Target
Area
Parameter
Bench
Mark
Target FY FY Q1 Q2 Q3 Q4 M
Kaizen by all Employee:
Cell Members
Supervisors
Staffs
Managers
2 Kaizen / Man / Month
Management by System:
Internal Audit
Internal Review Mechanism
Manpower Skill Enhancement
Need base training to all Team Members
Daily Work Management for:
Plant Head

5. ► TPM ACTIVITY ROADMAP OF PLANT
Target linking to :
Cell Level :
Target driven activity at cell level by PQCDSM way.
Pillar Level :
Plant Target linked to Pillar chairman with respect to Roadmap of Activities
Support Function Team:
Plant Target linked to support function:
Purchase
Store
Dispatch
PPC
Finance HR

6. ► TPM ACTIVITY ROADMAP OF PLANT
Plant Head’s Review Calendar
No.
Review
Time
Month: W1 W2 W3 W4 I
Cell Level Performance:
Target Driven Activity
PQCDSM way Improvement
1 Hr.
(1 Cell/Week)
Cell 1
Cell2
Cell 3
Cell 4 II
Pillar Activities:
As per Pillar Roadmap
(2 Pillar/Week) QM KK JH PM DM
OTPM
SHE
E&T
III
System Control:
Quality System
Safety System
Development System
Tier Vendor Audit System
0.5 Hr.
(1 Topic /Week)

7. ► TPM ACTIVITY ROADMAP OF PLANT
Pillar Activity Roadmap
1. KK – Kobetsu Kaizen
Area
Parameter FY FY Q2 Q3 Q4 Q1 P
OEE
16 Loss Monitoring
Corr. Actions & Kaizens M7 M8 M9
M10
M11
M12 M1 M2 M3 M4 M5 M6
Production/Hour
Debottlenecking of bottle neck operation by cycle time study
Output/Man
Study Line Organization Loss
Motion loss monitoring
Kaizens on it C
Cost Reduction
Cost loss Monitoring & Corr. Actions with Kaizens
Mfg. Variable cost reduction Kaizen D
Mfg. Lead Time Reduction Kaizen

8. ► TPM ACTIVITY ROADMAP OF PLANT
Pillar Activity Roadmap
2. QM – Quality Maintenance
Area
Parameter FY FY Q2 Q3 Q4 Q1 Q
Customer Complaints:
Streamline Final Inspection Activities M7 M8 M9
M10
M11
M12 M1 M2 M3 M4 M5 M6
In House Rejection:
Defect Monitoring and corr. Actions
QA Matrix
Corr. Actions on Happen & May Happen Def.
4M1T Control (IPO) for Sustenance
Critical to Quality Points linkage to : TFM/Pro. Quality/Mate. Handling
Internal Quality Audit System:
Product Audit
- 3 Level Inspection
- Layout Inspection
Process Audit
Material Handling Audit

9. ► TPM ACTIVITY ROADMAP OF PLANT
Pillar Activity Roadmap
3. JH – Jishu Hozen
Parameter FY FY Q2 Q3 Q4 Q1
JH STEP - 0
1S 2S Activity
Know Your Machine
Know Safety
Prepare For JH M7 M8 M9
M10
M11
M12 M1 M2 M3 M4 M5 M6
JH STEP - 1
Cleaning with Meaning
Cleaning for Inspection
Inspection for Abnormalities Finding (CLIRt)
Hard to access
Source of Contamination
Abnormality tagging by putting Red & White Tag
JH STEP - 2
Removal of Red & White Tag related Ab.
Hard Access made easy
Corr. Action on source of contamination

10. ► TPM ACTIVITY ROADMAP OF PLANT
Pillar Activity Roadmap
3. JH – Jishu Hozen
Parameter FY FY Q2 Q3 Q4 Q1
JH STEP - 3
Prepare Tentative Standards for CLIRt
Visuals on Machine for CLIRt
Self Audit
Kaizens on Abnormalities
JH Kaizen to reduce JH Time Activity M7 M8 M9
M10
M11
M12 M1 M2 M3 M4 M5 M6
Benefit of JH Activity:
Zero Breakdown due to weak JH
Zero Accident due to weak JH
Zero Defect due to weak JH

11. ► TPM ACTIVITY ROADMAP OF PLANT
Pillar Activity Roadmap
4. PM – Preventive Maintenance
Area
Parameter FY FY Q2 Q3 Q4 Q1 P
Achieve Zero Breakdown & Sustain
Why why Analysis of each Breakdown
Update in System (JH/PM/TBM )
Horizontal Deployment M7 M8 M9
M10
M11
M12 M1 M2 M3 M4 M5 M6
Support to JH
JH training to Cell Member
Support for removal of Abnormalities
Support for JH Kaizens
PM Activity
PM Schedule & Corr. Action on PM Ab.
TBM Schedule & Study replaced parts for improve Life improvement
TFM Schedule & Corr. Action on Ab. C
Maintenance Cost Reduction
MTTR Kaizen
MTBF Kaizens

12. ► TPM ACTIVITY ROADMAP OF PLANT
Pillar Activity Roadmap
5. SHE – Safety, Health & Environment
Area
Parameter FY FY Q2 Q3 Q4 Q1 S
Safety Awareness training
Repeated Safety Training
Safety Audits
Corr. Actions on unsafe condition
Capturing near miss incident M7 M8 M9
M10
M11
M12 M1 M2 M3 M4 M5 M6 H
Occupational Health Hazards due to Process
Study ergonomic conditions & actions
Working ambience
Health Check up E
Pollution Control due to Process
Protecting of Air / Land / Water pollution
Monitoring MPCB Norms & improvements
Preservation of Natural Resources
Energy (Water/Power) Saving
Prevention of Plastic / Thermo Cole use
Green Area Improvement

13. ► TPM ACTIVITY ROADMAP OF PLANT
Pillar Activity Roadmap
6. DM – Development Management
Parameter FY FY Q2 Q3 Q4 Q1
MP System:
New is much better
Past Learning Kaizens
MP Sheet Library
Design Guidelines /Standards/ Checklist to ensure on time use of MP sheets M7 M8 M9
M10
M11
M12 M1 M2 M3 M4 M5 M6
New Product/ Equipment/ Process Development:
Development Lead time Reduction
First time OK Sample
Productionise process with Zero Defects
Vertical Ramp with Zero IHR from day 1st

14. ► TPM ACTIVITY ROADMAP OF PLANT
Pillar Activity Roadmap
7. E&T – Education & Training
Parameter FY FY Q2 Q3 Q4 Q1
JH STEP 4 Training :
Know why manual
Training Centre
5 Axis training
Training Schedule M7 M8 M9
M10
M11
M12 M1 M2 M3 M4 M5 M6
Need Base Training:
New / Old Production Cell Member
Maint. Member
Supervisor
Staff

15. ► TPM ACTIVITY ROADMAP OF PLANT
Pillar Activity Roadmap
8. OTPM – Office TPM
Parameter FY FY Q2 Q3 Q4 Q1
Support Function:
Identify Support Function:
Purchase / Store / Dispatch / PPC / HR / Finance
Support to Production Shops
Identify Loss from Mfg. side & Office side
Corr. Actions and Kaizen on it
Own Office improvements M7 M8 M9
M10
M11
M12 M1 M2 M3 M4 M5 M6
Tier II Vendor Improvements:
Zero Quality defect
100% Delivery on time

16. TPM JOURNEY CONTINUES…
► THANK YOU…!
TPM JOURNEY CONTINUES…