Implementing Total Productive Maintenance (TPM) involves a change in the work culture and dedicated self-involvement of the top executives in the organisation. But the rewards have been reaped in the form of increased productivity, enhanced levels of quality, lower accidents and higher employee satisfaction.

The first milestone in TPM implementation was the creation of awareness, through a policy announcement in September 1995. A Master Plan setting the goals, and seeking the JIPM award by November 1999, was drawn up.

The second milestone saw managers becoming the models, through the practice of autonomous maintenance activities like cleaning, lubrication,tightening of fasteners, identifying sources of dust etc, which they took up from 11.15 to 12.00 noon daily. They earned the workers' respect and it led to the workmen taking up the cleaning of their machines voluntarily. A new work culture had been implemented.

The third milestone was the official kick-off ceremony marking entry into the TPM model in the presence of a local dignitary and a formal TPM oath being taken by all the employees.

The fourth milestone consisted of autonomous maintenance activities being carried out throughout the plant, with workmen forming circles, in charge of specific equipment which they maintained in model conditions. Documentation of such activities was done with charts, pictures and graphs on a board called `activities board'.

The fifth milestone was crosssed with the analysis and documentation of all maintenance activities through a transparent and participative system enabling people concerned to understand the lessons learnt in TPM implementation. This included before and after photographs of equipment being prominently displayed and analysis of man-hours spent on TPM, with their resulting benefits.

Under the sixth milestone, we continue with TPM activities in the following eight pillars:

• Focussed Improvement(FI)
  
  
• Autonomous Maintenance(AM)
  
  
• Progressive Maintenance(PM)
  
  
• Quality Maintenance(QM)
  
  
• Initial Flow Control(IFC)
  
  
• Education and Training(E & T)
  
  
• Office TPM(OTPM)
  
  
• Safety, Environment and Hygiene.(SHE)

As can be seen from the above, today TPM encompasses every sphere of activity at TANFAC, helping us to keep a highly motivated work force, high levels of productivity and quality, and satisfied customers.