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SARA TPM/WCM (Total Productive Maintenance/ World ClassManufacturing)

With competition becoming global, production technology is becoming increasingly sophisticated. To keepsuch plants running effectively, there is an urgent need to achieve zero defects, zero breakdowns and zero

accidents. This is the core of the Japanese concept of Total Productive Maintenance, which is similar to thewestern concept of World Class Manufacturing.

SARA TPM/WCM facilitates the implementation of all the eight pillars of Total Productive Maintenanceincluding focused improvement, autonomous maintenance, plant maintenance, office maintenance, MPDesigns and equipment initial control, statistical process control, quality control, worker's education &training, safety, hygiene & environment control. Based on customer inputs, SARA has added one moremodule - Customer Feedback - to measure client satisfaction after TPM/WCM is implemented in a factory.

Focused Improvement module covers implementation steps, registration of improvement topic, improvementtargets, the result of improvement and focused improvement audit.

The Autonomous Maintenance covers the Autonomous Activities, Maintenance Tags, One Point Lessons,

Equipment Evaluation Criteria, Abnormalities and Counter Measures and Autonomous Maintenance Audit.

The Plant Maintenance module covers the Maintenance Activities, Spares Required, Maintenance Procedure,Time Based Maintenance, Condition Based Maintenance, Inspection Schedules, Shutdown Maintenance,Calibration of instruments etc.

The Office Maintenance covers the office functions, document analyzing forms, daily work survey,daily/monthly work summary, monthly load charts etc.

The Quality Maintenance covers the quality maintenance aims, quality defect factors, present status ofprocess, analysis of 4M (Men, Machines, Materials and Methods), Counter Measures, Quality Improvement,and Quality Variation etc.

Workers Education and Training module covers worker's skills, training needs, training programs, trainingschedules, training infra-structure, programs attended by workers, improvement in workers' skills etc.

Safety, Hygiene and Environment Control covers the safety training, emergency handling procedures, safetymanuals, health check up of employees, pollution control checks and their results, safety and hygiene audit.

Customer Feedback module covers the customer complaints and their linkage with production, complaintredresses, effect of complaint and actions to be taken.

Modules of SARA TPM/WCM:

Focused improvement Autonomous maintenance Plant Maintenance Office Maintenance Product Design and Equipment Initial Control Quality Maintenance Workers Education & Training Safety, Hygiene & Environment Control Customer Feedback

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SARA's applications have been successfully implemented in India, Indonesia, Malaysia, Thailand, etc.