Maintenance of Plant & Machinery

Maintenance of Plant & Machinery

Maintenance plays a crucial role in the engineering and process industries. A plant may be regarded as successful when it operates without interruptions, which can however be achieved only when its facilities are in perfect working order at all times. The strategic importance of maintenance increases with increasing sophistication.

In a typical Industrial Scenario, the situation prevailing in the past has been:

  • 55% Reactive Maintenance
  • 31% Preventive Maintenance
  • 12% Predictive maintenance, and
  • 2% others.

Today, the focus of maintenance approaches within industry clearly has shifted from "reactive" to "proactive".


Examples of Successful Maintenance Strategies that SMEs Can Emulate




Note: All the companies featured in the examples have in one way or the other practiced “Jishu Hozen”, a Japanese word for “Autonomous Maintenance”. This form of maintenance is one of the important pillars of a concept known as “Total Productive Maintenance (TPM)”.


Total Productive Maintenance

TPM is a concept originated and developed by Japan Institute of plant Maintenance (JIPM) Tokyo, since late sixties. JIPM-TPM is the key for the operational excellence for many Japanese companies.

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

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.

Please download "All About TPM" to read further. The document provides:

  • The ‘whats’ and ‘whys’ of TPM
  • History of TPM
  • Types of maintenance
  • Objectives and Benefits of TPM
  • Step-by-Step Guide to TPM