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Applying Total Productive Maintenance in Auto Sector: A Case Study with Sona Koyo Group Gurgaon

Author Name : Sandeep Kumar, Pardeep Gahlot

ABSTRACT The manufacturing industries have gone through significant change in the last two-three decades and the competition has increased very rapidly. The main focus of the customers is on product quality, product delivery time and the cost of product. The cost of operation and maintenance should be economical. The cost of operation and maintenance can make or break a business, especially with today’s increasing demand on productivity, availability, quality, safety and environment Total productive maintenance (TPM) is a maintenance program which involves a newly defined concept of maintaining plants and equipments. TPM is a methodology that aims to increase the availability of existing equipment hence reducing the need for further capital investment. .It sets out to achieve these goals by analysis of previous historical records of product defects, equipment failure and accidents. A detailed case study on the journey of TPM in an auto-sector industry namely Sona Koyo Steering Systems Limited, Gurgaon is done. Normally the TPM implementation is a three to four years process and in Sona Koyo Steering, Gurgaon it implemented in 2000. Sona Koyo Steering, Gurgaon initiated TPM implementation through a consultant with an aim to implement all the eight pillars of TPM in a phased manner. The objective of this thesis is to study the implementation plan followed by Sona Koyo Steering, Gurgaon and find out the tangible as well as intangible benefits derived at different stages. The objectives, targets and implementation method of all the eight pillars are studied and enumerated. The case study can give insight and help the other industries in implementing TPM successfully in an efficient manner.