Saturday, May 29, 2021

Self Confidence Vs Over confidence

There are two types of people: realistic and idealistic. Both are needed for the betterment of society. Idealistic people need to develop a little practical wisdom to execute their ideas according to changing circumstances and should be a little liberal to accept slight modification & adjustment in the practical field to work out there plans successfully. 

But if they stick to their ideology without realizing practical difficulties, if they never try to listen to the people who are experts in execution because of their practical experience and working skill, and are unwilling to accept any advice from anybody, they can be called over confidence people.

For example, he who has never got into a plane trying to occupy the seat of the pilot, or one who has never held a gun is ready to go to battle field or a person terribly afraid of water trying to cross the ocean by swimming. 

What happened to the great warrior Abhimanyu though a courageous, heroic and bold but a bit over confidant? He knew how to enter into the labyrinth but did not know how to come out of it. He thought that somehow he would be able to manage. 

His over-confidence cost him his life. Duryodhana also committed the same mistake, He knew the strength of Pandavas, whom sir Krishna himself was protecting. Over confidant Duryodhana underestimated the strength of his opponents and lost everything.

Again there are people of tremendous capacities to perform wonders but who are not aware their own strength. They always undermine their abilities and try to avoid the task. All they need is the little motivation, reminder and inspiration.

The moment you awaken that giant within them they will do wonders.


Mahavir hanuman had all power and strength within him to cross the ocean but he was not aware of that. When Jambavan reminded him of his strength, his confidence was awakened and he reached Ceylon jumping across the ocean in search of Mother Sita.



Also Read - 

Useful Links to Read: 01. history-of-total-productive-maintenance 

Wednesday, May 19, 2021

Why Implement Total Productive Maintenance

Implementation of TPM Is Changing the Mindset of the Organization.


Need for Change :-

Organizational change is needed in order to align the company with changing business environment.

TPM emphasizes proactive and preventative maintenance to maximize the operational efficiency of equipment. It blurs the distinction between the roles of production and maintenance by placing a strong emphasis on empowering operators to help maintain their equipment.

The implementation of a TPM program creates a shared responsibility for equipment that encourages greater involvement by plant floor workers. In the right environment this can be very effective in improving productivity (increasing up time, reducing cycle times, and eliminating defects).

There are external and internal factors which necessitate the Change.

External and Internal Factors

External factors:

Market volumes, changing product profile, competition on price and variety, stringent product specifications, change in business environment driven by government Policies etc.,

Internal factors:

skills of employees, present plant technologies with respect to future product specifications driven by customers, level of productivity, Quality, cost and morale of employees.


Useful Links to Read:
01. history-of-total-productive-maintenance.html


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History of Total Productive maintenance

Since the introduction of PM, the predecessor of TPM, to Japan in 1951, Seiichi Nakajima has dedicated over half century to influence the concept of PM and TPM as a leader, and continues to this day. In these days, increasing numbers of TPM Award winners in overseas evidence that over 50 years of his committed effort is a genuine and valuable dedication to not only the Japanese manufacturing industry but also for manufacturing industry all over the world. Without his remarkable effort, TPM and manufacturing industry would not have been what it is today.




History of TPM and the Present Style

TPM is a unique Japanese systems of managerial expertise.

Developed from PM (preventive maintenance)style of US in 1950s.

Subsequently developed to its present state by JIPM

Now, TPM promotes entire company structures every line of businesses and all parts of the world.

TPM is implemented company wide.




TPM Principles :

The eight pillars of TPM are mostly focused on proactive and preventive techniques for improving equipment reliability:

  1. Autonomous Maintenance - Operators who use all of their senses to help identify causes for losses
  2. Focused Improvement - Scientific approach to problem solving to eliminate losses from the factory
  3. Planned Maintenance - Professional maintenance activities performed by trained mechanics and engineers
  4. Quality management - Scientific and statistical approach to identifying defects and eliminating the cause of them
  5. Early/equipment management - Scientific introduction of equipment and design concepts that eliminate losses and make it easier to make defect free production efficiently.
  6. Education and Training - Support to continuous improvement of knowledge of all workers and management
  7. Administrative & office TPM - Using TPM tools to improve all the support aspects of a manufacturing plant including production scheduling, materials management and information flow, As well as increasing moral of individuals and offering awards to well deserving employees for increasing their morals.
  8. Safety Health Environmental conditions


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Mobile Phone Handling - Important tips

Every time there’s news of another mobile phone battery exploding. It creates panic waves across the consumer landscape. Some time batteries explode due to glitch in the manufacturing process, which a results in a sub-standard batch. At such times manufacturers always call back the faulty product & replace it for free. It’s therefore always advisable to keep an eye and ear open to such announcements that are always accompanied by instructions on how to identified whether your battery is apart of that faulty batch or not.

Many other times, however, batteries may explode if they are poorly handled. Here are a few tips to make sure that you are handling your mobile phone & battery in the right way.



1) Firstly, avoid overcharging your phone battery. A longer charging time does not mean that your phone battery will last longer. Not at all!

2) Don’t use incompatible and unauthorized mobile phone batteries and chargers many incidents of exploding gadgets have involved counterfeit products in fact? Many manufacturers now publish guides to help identify fakes. At any point of time, if you have any question about the compatibility of a product with your mobile phone, contact an authorized dealer for advice. And yes, never buy or use batteries that are improperly/ suspiciously packaged look damaged or dented.

3) Similarly if you damage your phone battery in any way replaced it immediately especially since such batteries are more prone to exploding.

4) Also never carry your battery in your pocket or store it in your purse.
Contact with other metal objects in these places could harm the batteries terminals.

5) Don’t keep or store your mobile phone in or around areas that are hot.
This includes cooking surfaces near a cloths iron and even the glove compartment in your cars.

6) Never use a mobile phone that’s hot to touch .Over heated mobile phones and batteries can cause serious injuries also unplug the charging phone immediately if there are sings that the phone or batteries over heating. Get the phone checked by an authorized dealer
Before using it again.

7) Alternatively, don’t get the battery wet. During monsoons, make sure your phone is stored with in a dry encasing so as to avoid any untoward incident.



8) Keep your phone clean by using a clean and soft cloth. Avoid using any specially formulated liquids for the purpose.

Useful Links to Read:
01. history-of-total-productive-maintenance.html 02. why-implement-total-productive.html
03. what-is-tpm.html 04. 12-steps-for-tpm-implementation.html
05. typical-tpm-organizational-chart.html 06. effectiveness-of-tpm.html
07. 5-principles-in-tpm-development.html08. purpose-and-main-activities-of-kk.html
09. purpose-and-activities-of-jh-pillar.html 10. purpose-activity-of-pm-pillar.html
11. purpose-activities-of-qm-pillar.html 12. purpose-and-activity-of-dm-pillar.html
13. purpose-and-activity-of-otpm-pillar.html 14. purpose-and-activity-of-e-pillar.html
15. purpose-and-activity-of-she-pillar.html 16. company-wide-tpm.html
17. jishu-hozen-information.html 18. ishu-hozen-equipment-deterioration.html
19. role-of-production-maintenance-in-jh.html 20. jishu-hozen-step-1.html
21. 1s-2s-implementation.html 22. jh-step-01-abnormalities.html
23. exposing-seven-types-of-abnormality.html 24. 2-unfulfilled-basic-condition.html
25. 3inaccessible-places.html.26. 4-contamination-sources.html.
27. 5-quality-defect-sources.html. 28. 6-unnecessary-non-urgent-items.html.
29. 7-unsafe-places.html. 30. jishu-hozen-step2.html.31. jishu-hozen-step-3.html.
32. one-point-lesson-opl.html.33. visual-control-visual-management.html.
34. 35.
what-is-smed 36. why-energy-conservation


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Wednesday, May 12, 2021

12 Steps for TPM Implementation

Introduction-preparatory stage:

Step 1: The top person's declaration of the resolve to introduce TPM 

The declaration is made in an internal TPM lecture meeting, and should be printed in an internal bulletin or newsletter. 

Step 2: TPM introduction education. 

Managerial staff: Staff of the same echelon are scheduled together for training General employees: Slide-show meetings 

Step 3: Formation of TPM promotion organizations and formal organizational 

models Committees, specialized subcommittees, promotion secretariat Formal organization models 

Step 4: Setting of basic TPM principles and targets 

Benchmarks and targets; prediction of effects 

Step 5: Preparation of a master plan for implementing TPM 
From preparation for introduction to undergoing examinations Start of introduction

Step 6: Kick off of TPM Customers, affiliated companies, and cooperative companies are invited Introduction-execution stage

Step 7: Establishment of a system for improving the efficiency of the production department 

Pursuit of improvement of efficiency in the production department 
7.1: Kobetsu-Kaizen Project-team activities and workshop small-group activities 
7.2: Jishu-Hozen Step method, diagnosis, and approval certificates 
7.3: Planned maintenance Corrective maintenance, periodic maintenance, predictive maintenance
7.4: Operation/maintenance skill development Collective education of leaders & education concerning transmission of education to members Introduction-execution stage 

Step 8: Establishment of initial phase management systems for new products & new equipment Development of easy-to-manufacture products and easy-to-use equipment 

Step 9: Establishment of quality maintenance systems 
Creation of conditions in which defects do not occur, and the maintenance/management of those conditions. 

Step 10: Creation of systems for improvement of the efficiency of administrative/supervisory sectors. 
Production support, improvement of the efficiency of related sectors, and improvement of efficiency of equipment. 

Step 11: Creation of systems for the control of safety, health, and the environment Creation of systems for zero accidents and zero pollution cases Establishment stage

Step 12: Complete implementation of TPM and level improvement 
Undergoing examinations for the receipt of PM awards; Setting sights on higher targets.

Useful Links to Read: 01. history-of-total-productive-maintenance.html 02. why-implement-total-productive.html 03. what-is-tpm.html