Implementation of total productive maintenance (TPM) to increase overall equipment efficiency of an hotel industry

Abstract. Hotel industries are one of the fastest growing areas in India, which is attracting more number of jobs & tourists. This also results in direct impact on Indian economy. All Hotels comprises a higher element of total working cost and they are a good source of income. Hospitality is one of the most important components of hotel industry. To give a good hospitality in hotels to customers, we need to use different machines in different departments. For example if we take section of housekeeping it consists of different sub departments like Rooms & corridors, Toilets, Linen, Furniture and furnishings, Gardens, Public areas etc. In this connection a small implementation of TPM tool called focused improvement & planned maintenance, implemented in alternative usage of electrical systems (energy conservation). Result showed a very significant improvement in energy saving. By adopting Small changes show a significant improvement in the overall system. It also indicates the dire need of proper industrial tools in hotels. Total Productive Maintenance (TPM) is one of the pioneering approaches which can be achieved in above said things [1][2].


Introduction
It is well known fact that in industrial situation huge losses/wastage occur in the manufacturing shop floor. It happens due to operators, maintenance personal, process, tooling problems and non-availability of components in time and many more. Indirect or hidden waste includes idle machines; idle manpower, machine break down, rejected parts etc. are all examples of waste [3]. Quality is very significant factor as they matter the company in terms of time, material and the hard earned reputation of the company. In recent trends companies are leaning towards Zero tolerance for waste, defects, break down & zero accidents in all departments. In order to overcome these problems, a innovative concept such as TPM has been successfully implemented in many industries across the globe to address the above said problems.

Observation on electric energy consumption in a hotel
The electricity consumption details of 1 month collected from hotel management. In order to check the day to day variation in energy consumption, Ẍ and R chart were plotted using Minitab 17 software. The below tables represents Energy consumptions recorded (table 2) for the month of OCTOBER-Before optimization of electricity units.

Xbar-R Chart of units consumed/day
Tests performed with unequal sample sizes

Fig. 2. Xbar and R-charts for Electricity consumed in October (in units)
The above graph represents Xbar-R Chart of electricity consumed during the month of October and it shows that consumption of electricity is not under control

Implementation of tpm tool called focused improvement & planned maintenance
In simple words Focused improvement can be defined as a method that identifies the systems problems and then modifies the whole system in order to find the most cost effective, time saving and least disruptive solutions in order to optimize the system [6,7]. Planned maintenance is another tool where an object, item, or equipment are maintained in a planned manner to increase the efficiency by reducing the downtime. By adopting above methodologies the following suggestions were given. 1. Replaced incandescent bulbs with LED lights. 2. Introduced Fluorescent Ceiling Lights 3. Replaced the fixtures 4. Installed lower wattage or more efficient lamps Table 3 shows the differences between different bulbs to different parameters. Calculations: at Avg. Electricity cost Rs7.80 per unit, at usage of 10hr per day per year Frequent maintenance and check-ups of the devices in Hotel were carried out as part of planned maintenance. PM avoids the break-down and maintains the efficiency, productivity, energy consumption of the process. After implementation of the above said suggestions to optimize the energy savings, the data were recorded as showed in Table 4.
November-After implementation of the above suggestions

Xbar-R Chart of Units consumed/day
Tests performed with unequal sample sizes  The data shows only the one month energy or power consumption record, just by implementing small changes in the system. This small changes implementation has showed a significant improvement and increased profit in the system. The initial investment looks like a burden to the hotel management, but the outcome showed the profit to the Hotel industries. Many areas or departments are needed to be checked at the same time optimization can be achieved by TPM tools.