Itqan ® is considered one of the leading organization in the implementation of World Class Total Productive Maintenance – Programs that follows Kaizen-TPM Methodology.

TPM is an innovative Japanese concept. The origin of TPM (company wide) can be traced back to 1960 when preventive maintenance was introduced in Japan by a company called Nippondenso.

Preventive maintenance is the concept wherein, operators produced goods using machines and the maintenance group was dedicated with work of maintaining those machines, however with the automation of Nippondenso, maintenance became a problem as more maintenance personnel were required. So the management decided that the routine maintenance of equipment would be carried out by the operators. ( This is Autonomous maintenance, one of the features of TPM ). Maintenance group took up only essential maintenance works.

Since 2002, Itqan® introduced TPM in coordination with its affiliate partner Kaizen® Institute in GCC. We have a proven Successful Case Studies and Model References in the region that would help organizations understand the importance of TPM for productivity of Plants.
TPM program facilitated by Kaizen-Itqan Team of experts and consultants helps organizations to maintain the organization facilities in optimal condition with new and progressive productivity management techniques that delivers what is known today as Overall Plant Effectiveness (OPE).

TPM is about involving the maintenance department and process support personnel, equipment operators and the management team. Itqan-Kaizen Experts ensure that all those team members must work together to eliminate equipment breakdowns, reduce scheduled downtime, enhance productivity uptime and maximize utilization, throughput and quality.

Total Productive Maintenance provides the methods to measure and eliminate much of the non-productive time, if implemented properly. Itqan® and Kaizen® Methodologies guarantees that the Overall Plant Effective (OPE) and Overall Equipment Efficiency (OEE) can be improved in each 5 days workshop through working directly.

The goal of the TPM program is to markedly increase production while, at the same time, increasing employee morale and job satisfaction. In Itqan® we guarantee these results through our Kaizen-Itqan team of experts.

TPM brings maintenance into focus as a necessary and vitally important part of the business. It is no longer regarded as a non-profit activity. Down time for maintenance is scheduled as a part of the manufacturing day and, in some cases, as an integral part of the manufacturing process. The goal is to hold emergency and unscheduled maintenance to a minimum.

How Itqan® can help your organization introduce TPM Programs?
Itqan® focuses on TPM programs as part of its Change Management leadership in the region. Itqan® programs helps your organization to:

• Avoid wastage in a dynamic changing economic environment.
• Establishing techniques that are effective in producing goods without reducing product quality and also would support reducing cost.
• Producing a low batch quantity at the earliest possible time.

Itqan® TPM Awards and Excellence Programs

In order that Autonomous maintenance turned to be done by production operators and maintenance crew continuously innovate in doing equipment modification that would improve the reliability ; organizations started to put their own TPM Excellence Award that would result in maintenance prevention culture. Thus preventive maintenance along with Maintenance prevention and Maintainability Improvement gave birth to Productive maintenance. The aim of productive maintenance was to maximize plant and equipment effectiveness to achieve optimum life cycle cost of production equipment.

TPM the Japanese way focuses on culture of quality circles which is based on involving the employees in implementing Productive maintenance. Hence, the Japanese Institute of Plant Engineers ( JIPE ) have created an award that would distinguish plants that manage to develop and implement TPM.

Itqan® can prepare your organization to JIPM® Award which a distinguished award along with other world class industrial management awards that would be a means only to show an appreciation of higher productivity and profit management of your industry core of business.

Itqan® and Kaizen® TPM Programs guarantee:

- Minimum of 80% OPE ( Overall Plant Efficiency ) or at least 1.5 time.
- Minimum 90% OEE ( Overall Equipment Effectiveness )
- A Culture that run the machines even during lunch as it is would be believed that it is for operators and not for machines !
- Your Organisation would operate in a manner, so that there are no customer complaints.
- Reduction of the manufacturing cost by at least 30%.
- Achieving 100% success in delivering the goods as required by the customer.
- Maintaining an accident free environment.
- Increasing the suggestions for innovative improvements from staff by 3 times.
- Develop Multi-skilled and flexible workers with Deskilling Techniques.
- Adoption of life cycle approach for improving the overall performance of production equipment.
- Improving productivity by highly motivated workers which is achieved by job enlargement
- Use of voluntary small group activities for identifying the cause of failure, possible plant and equipment modifications.
- Achieve Zero Defects, Zero Breakdown and Zero accidents in all functional areas of the organization.
- Involve people in all levels of organization.
- Teamwork to reduce defects ,self maintenance and rectify customer complaints.
- Higher confidence level among the employees.
- Higher ability Keep the work place clean, neat and attractive.
- Change in the attitude of the operators.
- Achieve goals by working as team.
- Horizontal deployment of a new concept in all areas of the organization.
- More willingness to share knowledge and experience.
- Feel of ownership towards Organisation Facilities.

Importance of TPM Itqan® and Kaizen® way to Developing Countries

With the high competition in industries in the global market and WTO open boundaries policies, TPM today may be the only thing that stands between success and total failure for many companies in developing countries. It has been proven to be a program that works and saves organizations lots of money with effective cultural change in an amazing time. This is one of the most important secret of Toyota© plants.

It can be adapted to work not only in industrial plants, but in construction, building maintenance, transportation, and in a variety of other situations.

Through TPM programs in Developing Countries we can have an effective and efficient Industrial Sectors that develops an educated and convinced about innovation and competitiveness.

In Itqan® and through our Kaizen-Itqan Experts we ensure that everyone is involved and hence we would guarantee an unusual high rate of return compared to resources invested.