The ISO 9000

The ISO 9000 family of quality management systems standards is designed to help

organizations ensure that they meet the needs of customers and other stakeholders

while meeting statutory and regulatory requirements related to a product or service.

ISO 9000 deals with the fundamentals of quality management systems, including

the seven quality management principles upon which the family of standards is

based. ISO 9001 deals with the requirements that organizations wishing to meet the

standard must fulfill.

The ISO 9000 series are based on seven quality management principles (QMP)

The seven quality management principles are:

Principle 1 – Customer focus: Organizations depend on their customers and

therefore should understand current and future customer needs, should meet

customer requirements and strive to exceed customer expectations.

Principle 2 – Leadership: Leaders establish unity of purpose and direction of the

organization. They should create and maintain the internal environment in which

people can become fully involved in achieving the organization's objectives.

Principle 3 – Engagement of people: People at all levels are the essence of an

organization and their full involvement enables their abilities to be used for the

organization's benefit.
Principle 4 – Process approach: A desired result is achieved more efficiently when

activities and related resources are managed as a process.

Principle 5 – Improvement: Improvement of the organization's overall performance

should be a permanent objective of the organization.

Principle 6 – Evidence-based decision making: Effective decisions are based on the

analysis of data and information.

Principle 7 – Relationship management: An organization and its external providers

(suppliers, contractors, service providers) are interdependent and a mutually

beneficial relationship enhances the ability of both to create value.

ADVANTAGES OF ISO 9000

The advantages associated with ISO 9000 certification are numerous, as both
business analysts and business owners will attest. These benefits, which can impact
nearly all corners of a company, range from increased stature to bottom-line
operational savings. They include:

 Increased marketability—nearly all observers agree that ISO 9000

registration provides businesses with markedly heightened credibility with
current and prospective clients alike. Basically, it proves that the company is
dedicated to providing quality to its customers, which is no small advantage
whether the company is negotiating with a long-time customer or
endeavoring to pry a potentially lucrative customer away from a competitor.
This benefit manifests itself not only in increased customer retention, but
also in increased customer acquisition and heightened ability to enter into
 new markets; indeed, ISO 9000 registration has been cited as being of
particular value for small and mid-sized businesses hoping to establish a
presence in international markets.
 A reduced operational expense—Sometimes lost in the many discussions of
ISO 9000's public relations cache is the fact that the rigorous registration
process often exposes significant shortcomings in various operational areas.
When these problems are brought to light, the company can take the
appropriate steps to improve its processes. These improved efficiencies can
help companies garner savings in both time and money. "The cost of scrap,
rework, returns, and the employee time spent analyzing and troubleshooting
various products are all considerably reduced by initiating the discipline of
ISO 9000, " confirmed Richard B. Wright in Industrial Distribution.
 Better management control—The ISO 9000 registration process requires so
much documentation and self-assessment that many businesses that undergo
its rigors cite increased understanding of the company's overall direction and
processes as a significant benefit.
 Increased customer satisfaction—Since the ISO 9000 certification process
almost inevitably uncovers areas in which final product quality can be
improved, such efforts often bring about higher levels of customer
satisfaction. In addition, by seeking and securing ISO 9000 certification,
companies can provide their clients with the opportunity to tout their
suppliers' dedication to quality in their own business dealings.
 Improved internal communication—The ISO 9000 certification process's
emphasis on self-analysis and operations management issues encourages
various internal areas or departments of companies to interact with one
another in hopes of gaining a more complete understanding of the needs and
desires of their internal customers.
 Improved customer service—The process of securing ISO 9000 registration
often serves to refocus company priorities on pleasing their customers in all
 respects, including customer service areas. It also helps heighten awareness
of quality issues among employees.
 Reduction of product-liability risks—Many business experts contend that
companies that achieve ISO 9000 certification are less likely to be hit with
product liability lawsuits, etc., because of the quality of their processes.
 Attractiveness to investors—Business consultants and small business owners
alike agree that ISO-9000 certification can be a potent tool in securing
funding from venture capital firms.

TOTAL PRODUCTIVE MAINTENANCE

Total productive maintenance (TPM) is a series of methods that ensures every

piece of equipment in a production process is always able to perform its required

tasks so that production is never interrupted. TPM helps you focus on and

accelerate the equipment improvements required for you to implement methods

such as one-piece flow, quick changeover, and load leveling as part of your

company’s lean initiative.

Types of maintenance:

1. Breakdown Maintenance: In this type of maintenance, no care is taken for

the machine, until equipment fails. Repair is then undertaken. This type of

maintenance could be used when the equipment failure does not

significantly affect the operation or production or generate any significant

loss other than repair cost. However, an important aspect is that the failure of

a component from a big machine may be injurious to the operator.

 2. Preventive Maintenance: It is a daily maintenance (cleaning, inspection,

oiling and re-tightening), design to retain the healthy condition of equipment

and prevent failure through the prevention of deterioration, periodic

inspection or equipment condition diagnosis, to measure deterioration.

3. Corrective maintenance: It improves equipment and its components so

that preventive maintenance can be carried out reliably. Equipment with

design weakness must be redesigned to improve reliability or improving

maintainability. This happens at the equipment user level. E.g. Installing a

guard, to prevent the burrs falling in the coolant tank.

4. Maintenance prevention: This program indicates the design of new

equipment. Weakness of current machines is sufficiently studied (on site

information leading to failure prevention, easier maintenance and prevents

of defects, safety and ease of manufacturing). The observations and the

study made are shared with the equipment manufacturer and necessary

changes are made in the design of new machine.

5S Foundation
5S is considered the foundation of the lean TPM program because without it the
initiative will founder under the weight of disorganization, indiscipline and
inefficiency.

It is important because it results in a clean, visually organized workplace that is

self-maintaining. 5S consists of five basic steps:
  Sorting all the items in the workplace and removing everything that is not
necessary and does not contribute to the creation of value for the customer

 Setting in Order everything that remains in an organized manner such that

find items and raw materials is easy. This reduces waiting and searching time
in the process enhancing the flow of value throughout the value chain

 Shining (Cleaning) is a way of making any abnormalities visible as well

ensuring that quality of the final product is of a high standard. It has been
observed that a clean and organized workplace has a positive effect on worker
morale, not to mention that it also ingrains a sense discipline – all of which has
an impact on overall productivity

 Standardizing ensures that the improvements made are documented for

posterity as well as serving as a basis for further improvements and training

 Sustaining the improvements through scheduled audits is a way of stabilizing

the system by ensuring the agreed standards are been followed. Audits also
serve as a measure of the effectiveness of the established standards – feedback
that can be used to determine whether the standards need further revision or
improvement.

The 8 Pillars of TPM: TPM aims to increase productivity, efficiency

and safety by empowering operators and team leaders to play a proactive role in
day-to-day lubrication, inspection and cleaning. Management is tasked with
creating a "buy-in culture" to support continuous activities through eight pillars of
activity. The eight pillars of TPM are:

i. Autonomous Maintenance — Operators monitor the condition of their own

equipment and work areas.
 ii. Process and Machine Improvement — Team leaders collect information
from operators and work areas, and then prioritize preventive maintenance
and improvements.
iii. Preventive Maintenance — Operators and team leaders share preventive
maintenance tasks and schedules.
iv. Early Management of New Equipment — Team leaders anticipate and
plan for parts of equipment life cycles and report to mangers based on
maintenance reports.
v. Process Quality Management — Shared responsibility for operation and
maintenance encourages quality improvement ideas from all areas of work.
vi. Administrative Work — Managers prioritize data from the previous pillars
and share outcomes with team leaders and work areas.
vii. Education and Training — Continuous improvement includes operator and
work area education and training, which improve morale, retention and
efficiency.
viii. Safety and Sustained Success — Facility-wide safety is prioritized, which
positively impacts sustained success of the TPM program.

BENEFITS OF TPM:

Direct Benefits of Total Productive Maintenance

 Increase in productivity and Overall Plant Efficiency by 1.5 or 2 times.
 Customer complaints are rectified swiftly.
 Manufacturing cost is reduced considerably by up to 30%.
 As the right quantity in the required quality is delivered to customer at the
right time, their needs are satisfied by 100%.
 Accidents are reduced considerably.
 Decrease in pollution levels by following pollution control measures.
Indirect Benefits of Total Productive Maintenance
 Total productive Management ensures higher confidence level among the
employees.
 Better upkeep of the work place by making it clean, neat and attractive.
 Favorable change in the attitude of the operators.
 TPM helso to achieve the preset goals by working as group.