Role Purpose:

To drive Total Productive Maintenance (TPM) culture across the plant by implementing and sustaining 5S workplace management, and supporting TPM all 8 pillars to improve productivity, quality, safety, and cost efficiency in the furniture and mattress manufacturing operations.

Key Responsibilities

1. 5S Implementation & Sustenance

- Assist implementation of 5S across production and support areas.
- Conduct regular 1S2S audits and ensure compliance across departments.
- Develop visual workplace standards including markings, tagging, labeling, and storage systems.
- Monitor sustenance through audit scores, gap closure, and continuous improvement actions.
- Train operators and supervisors, Managers on workplace organization and standard practices.

2. Kobetsu Kaizen (KK) Focused Improvement

- Monitor loss elimination projects related to productivity, quality, breakdown, and material wastage.
- Facilitate cross functional kaizen activities in production lines.
- Track cost savings and performance improvements from kaizen initiatives.

3. Jishu Hozen (JH) – Autonomous Maintenance

- Support implementation of JH steps for production operators.
- Develop CLIT (Cleaning, Lubrication, Inspection, Tightening) standards for machines.
- Train operators on basic equipment care and abnormality detection. - DETs
- Maintain abnormality tagging and closure tracking system.

4. Quality Maintenance (QM)

- Support quality teams in identifying quality defects related to equipment or process conditions.
- SOP audit, Why-why compliance, Process change note adherence.
- Ensure quality checkpoints and control standards are maintained.
- Assist in implementing Poka-Yoke and defect prevention systems.




- Track quality losses and corrective actions.

5. Planned Maintenance (PM)

- Coordinate with the maintenance team to ensure preventive maintenance (PM) schedules are followed.
- Support implementation of maintenance planning systems and breakdown analysis.
- Monitor MTBF, MTTR, and machine downtime data.
- Help develop maintenance checklists and standard procedures.

6. Education & Training

- Conduct TPM awareness and pillar training programs for shopfloor employees.
- Support documentation such as OPLs, SOPs, and training materials.

7. Culture Transformation

- Drive a continuous improvement culture across the plant.
- Promote employee ownership of equipment and workplace discipline.
- Facilitate cross-functional team engagement in improvement activities.
- Lead initiatives that strengthen problem-solving and accountability mindset.

8. Training & Development of GETs

- Design and implement a structured development program for Graduate Engineer Trainees (GETs).
- Train GETs in:
- TPM fundamentals
- Industrial Engineering concepts
- Problem solving tools
- Manufacturing excellence practices
- Assign practical improvement projects and mentor them for execution.
- Track skill development and progress of trainees.

9. Continuous Improvement Projects

- Identify cost reduction, productivity improvement, and waste elimination opportunities.
- Facilitate Kaizen activities and improvement workshops.
- Implement structured problem-solving methodologies.

10. Review and monitoring

- Establish TPM review systems at different levels (daily, weekly, monthly).
- Prepare and present TPM progress reports to plant leadership.
- Ensure alignment of TPM activities with plant performance goals.

📌 TPM Manager (Hosur)
🏢 WAKEFIT INNOVATIONS
📍 Hosur