Operations
/ Chemicals [ India ]
6 months
TPM Implementation Expert for Manufacturing Plant
CLIENT:
Leading Big4 Consulting Firm
CONSULTANT:
A senior manufacturing professional with 40+ years of industry experience across reputed Indian and multinational organizations, including ABB Ltd., KOCH Engineered Solutions, Eimco Elecon (I) Ltd., GCEL, Elecon Engineering Company Ltd., ADI Infosystems Pvt. Ltd., Electronica Machine Tools Ltd., Kinnari Printing Technologies Pvt. Ltd., EMCO Transformers Ltd., and Bell Ceramics Ltd.
Brings 10+ years of hands-on experience in JIPM TPM implementation, 5+ years of experience in TPM education and training, and 3+ years of experience providing TPM consulting services. Has supported the implementation of JIPM Total Productive Maintenance (TPM) across manufacturing organizations and delivered training programs to build internal capability.
Core expertise includes Total Productive Maintenance (TPM), 7-Step Kobetsu Kaizen, Makigami Analysis, Value Stream Mapping, Gemba Walk, OHNO Circle, SMED, Poka-Yoke, Kaizen, 5S, Visual Management, and Industrial Engineering techniques such as Time & Motion Study, MOST (Maynard's Operation Sequence Technique), Line Balancing, and Plant Layout.
Brings 10+ years of hands-on experience in JIPM TPM implementation, 5+ years of experience in TPM education and training, and 3+ years of experience providing TPM consulting services. Has supported the implementation of JIPM Total Productive Maintenance (TPM) across manufacturing organizations and delivered training programs to build internal capability.
Core expertise includes Total Productive Maintenance (TPM), 7-Step Kobetsu Kaizen, Makigami Analysis, Value Stream Mapping, Gemba Walk, OHNO Circle, SMED, Poka-Yoke, Kaizen, 5S, Visual Management, and Industrial Engineering techniques such as Time & Motion Study, MOST (Maynard's Operation Sequence Technique), Line Balancing, and Plant Layout.
ASSIGNMENT:
The client is was for an experienced TPM professional to lead implementation in a manufacturing plant (preferably in the chemical industry or any asset-intensive environment), improve operational efficiency, and build internal capability through training sessions. The role involves onsite delivery, conducting TPM implementation, and training plant personnel. The role required active involvement in shop-floor execution, including deploying TPM practices, working closely with plant teams, identifying improvement areas, and ensuring practical implementation of maintenance excellence initiatives.
OUTCOME:
The TPM implementation resulted in improved equipment reliability, increased Overall Equipment Effectiveness (OEE), and a measurable reduction in equipment downtime and maintenance losses. Standardized maintenance processes and autonomous maintenance practices enhanced shop-floor ownership and operational discipline.
The engagement also strengthened the organization's internal capability through structured training and coaching, enabling plant personnel to independently sustain TPM initiatives beyond the implementation phase. By embedding continuous improvement practices and preventive maintenance culture, the project established a strong foundation for long-term operational excellence, higher productivity, and improved manufacturing performance.
The engagement also strengthened the organization's internal capability through structured training and coaching, enabling plant personnel to independently sustain TPM initiatives beyond the implementation phase. By embedding continuous improvement practices and preventive maintenance culture, the project established a strong foundation for long-term operational excellence, higher productivity, and improved manufacturing performance.