This study was done in a medium scale industry that manufactures tyres in Mysore. It has been observed that, the breakdown of some of the mills has been critical. Hence, it was decided to apply Total Productive Maintenance (TPM) concept to this industry. In this paper, we have collected the data of the breakdowns of a 4 roll calendar mill, a 4 roll calendar warm-up mill and a warm-up mill overhead conveyor and have discussed the remedial measures for reducing the breakdowns of the 4 roll calendar mill. Lean manufacturing tools like Cause and Effect diagram, Why-Why analysis and Kaizen techniques are applied for the analysis.

Total Productive Maintenance (TPM) plays an important role in effectively managing the machines and in improving the machine capability. TPM is not the same as a maintenance department that repairs breakdowns (breakdown maintenance). TPM is a critical adjunct to lean manufacturing. If machine up time cannot be predicted and process capability not sustained, then we cannot produce the sales at the rate at which they happen. TPM is not fixing machines, but is, `deterioration prevention' and `maintenance reduction'. For this reason, many people also refer to TPM as `Total Productive Manufacturing' or `Total Process Management'. TPM is a proactive approach that essentially aims to prevent any kind of slack before occurrence. Its motto is `zero error, zero work-related accident, and zero loss.'

TPM is considered to be the medical science of machines and is a maintenance program, which involves a newly defined concept for maintaining plants and equipment. The goal of the TPM is to markedly increase production, while, at the same time, increasing employee morale and job satisfaction.

Total Productive Manufacturing, Lean Manufacturing, Kaizen techniques, Total Process Management, Cleaning Lubrication Inspection and Tightening Graph, CLIT Graph, Innovation Management, Production Management, Inventory Management, Brain Storming, Strategic Maintenance.