GreenDot is India’s most result-oriented TPM consultant, trusted by Atul Ltd, Castrol, Pidilite, JSW MI, Alltech and 1,200+ manufacturers since 1999. Unlike consultants who deliver training presentations and disappear.
Greendot Management Solutions provides TPM consulting and implementation services to help manufacturing companies improve equipment reliability, increase OEE, reduce machine breakdowns and downtime, and build a structured maintenance system.
Our TPM consultants work with plant leadership, production teams, maintenance teams and operators to assess current losses, develop a practical TPM roadmap, implement TPM pillars, strengthen autonomous and planned maintenance, and sustain measurable improvements.
Whether you are starting TPM, improving an existing TPM program, or looking to reduce recurring equipment losses, our approach combines assessment, implementation, training, measurement and continuous improvement.
Following are the tpm implementaiton steps, which assure you result.
Assess current maintenance practices, equipment losses, breakdowns, OEE, maintenance performance and TPM maturity to identify improvement priorities.
Develop and execute a practical TPM implementation plan covering the appropriate TPM pillars, pilot areas, teams, KPIs and improvement activities.
Create a phased TPM roadmap aligned with plant objectives, equipment priorities, production requirements and measurable improvement targets.
Help operators take ownership of routine equipment care through cleaning, inspection, lubrication, standards, abnormality identification and basic maintenance activities.
Strengthen preventive and planned maintenance systems to reduce breakdowns, improve equipment reliability and increase maintenance effectiveness.
Identify the major equipment losses affecting availability, performance and quality, and use TPM practices to improve OEE and reduce downtime.
Train operators, maintenance teams, supervisors and management in TPM principles, pillars, tools, standards and practical implementation.
Review TPM implementation, measure progress against defined KPIs, identify gaps and establish actions to sustain and improve results.
In continuous batch process industries, unplanned downtime, low machine efficiency, and inconsistent output silently eat into profits. Many industries face challenges like
Labour, utilities, and maintenance costs are higher due to inefficiencies.
Poor machine performance can triple operational costs due to scrap and rework.
Buying more machines without improving existing ones locks up capital unnecessarily.
Critical issues remain hidden, and management relies on guesswork.
Teams spend excessive time fixing recurring problems instead of working efficiently.
Many are unaware of the 16 major losses impacting productivity.
Competitors often sell at better prices while maintaining higher profitability.
The desire is clear: optimize machines, reduce costs, improve quality, and make smarter, data-driven decisions that directly impact profitability.
TPM is a holistic approach to maintenance that ensures machines, processes, and teams work efficiently, safely, and reliably.
The 8 TPM Pillars
Outcome: Higher OEE, safer operations, improved productivity, and a workplace that runs like a well-oiled machine.
We implement TPM in continuous batch process environments —
reactors, distillation columns, utilities and packaging lines.
Our consultants eliminate unplanned downtime, reduce raw material
losses through precision equipment control and build autonomous
maintenance routines that your operators run independently.
Results our chemical clients achieve:
– Unplanned downtime reduced by 40–60%
– Batch consistency improved by 25–35%
– Maintenance cost per unit reduced by 20–30%
Every TPM system we build in chemical plants is designed around
process safety and regulatory compliance — not just OEE numbers.
We implement TPM on CNC machines, press lines, fabrication Chemical plant, ,Equipment and assembly lines — maximising uptime, reducing. Changeover time and achieving measurable OEE improvement.
At Coptec New India Group: production increased from 15–18 units/month to 24 units/month — a 45.5% improvement — through OEE implementation and changeover optimisation. Zero new machines. Zero extra headcount.
Atul Ltd has worked with GreenDot for 5+ years across 86 no of multiple plants. That long-term relationship is our strongest proof of sustainable implementation.
GreenDot implemented Reliability Engineering across 40 manufacturing plants of Pidilite Industries — India’s largest specialty chemical company.
When Pidilite needed a TPM and reliability partner, they could trust across their entire manufacturing network, they chose GreenDot..
That is not a coincidence. That is a track record.
OEE (Overall Equipment Effectiveness) is the key metric to measure machine and process efficiency. It evaluates:
By improving OEE, companies can increase production without additional machines, reduce costs, and enhance profitability. TPM focuses on identifying losses, optimizing efficiency, and sustaining improvements to achieve measurable results.
TPM can work alongside Lean Manufacturing to improve equipment reliability, eliminate losses and support continuous improvement
Answer a few quick questions and get a clear snapshot of what’s working, what’s broken, and where to focus next.
Operators take responsibility for routine cleaning, inspection, lubrication and early abnormality detection.
Build systematic preventive and planned maintenance to reduce equipment failures and unplanned downtime.
Identify major losses and use structured problem-solving to eliminate their root causes.
Prevent equipment-related quality problems and improve process stability.
Apply equipment and maintenance learning when introducing new machines, processes or equipment.
Develop the skills required by operators, maintenance teams and supervisors to sustain TPM.
Integrate safe working practices and environmental considerations into TPM activities.
Reduce administrative and information-flow losses that affect manufacturing performance.
TPM can work alongside Lean Manufacturing to improve equipment reliability, eliminate losses and support continuous improvement
Total Productive Maintenance (TPM) drives continuous process improvement for industries where uninterrupted operations, efficiency, and quality are critical. Key benefits for continuous process industries include:
Maintain consistent batch and continuous output, minimize unplanned downtime, reduce hazards, and optimize raw material usage.
Improve equipment reliability, ensure compliance with quality standards, reduce batch rejections, and enhance operational predictability.
Streamline production processes, reduce machine breakdowns, optimize utility consumption, and improve OEE for higher throughput.
Achieve efficient resource utilization, standardized workflows, and measurable improvements in productivity and cost efficiency.
Production increased: 15–18 → 24 units/month
Overall impact: +45.5% increase in monthly production
Minimum gain: +6 units/month (+33.3%)
Maximum gain: +9 units/month (+50%)
OEE: Machine utilisation improved through structured
autonomous maintenance and daily OEE tracking
Changeover: Colour-change process optimised using SMED — time losses eliminated, output consistency achieved
Zero new machines. Zero extra headcount. Pure shop floor improvement by GreenDot mangement soltion.
If you’re ready to:
"Nirav has communication skills to get connected with hard working dedicated employees. He supports to bring each employee to visualize broad spectrum role. "
Atul Limited"Mr. Nirav Trivedi is an excellent coach both on personal and professional front. He has exceptionally curated his TQM course to identify gaps and increase productivity in sort span of time. I wish him and his team best of luck for all endeavors. "
Atul Limited
"A person with who can create a roadmap to build strong value and take you to the next level "
MAAK & Associates
"Had a very good experience working with Greendot Consultancy, we have been resulted into skill improvement and develop personal view to grow our company and how to balance industry in many aspects. "
Alltech Industries"Mr. Nirav Trivedi is a excellent business consultant we have work with so far. His advice as a consultant has allowed our organisation to expand our business tremendously. He has helped us to implement changes in our policies and strategies that have made our organization more efficient and profitable. He is costliest among all the consultants, but WORTH IT ! "
Alltech Industries
"Practical and Innovative way to resolve problems. Highly positive attitude. Implementation of suggested modification and changes is easier. "
Chiripal Polyfilms"Have been associated with Nirav's team, Green Dot for 2 years. These two years were quite focused on our objective and the goal set by the organization. Despite Covid lockdown we could achieve a successful milestone. Support extended by Nirav and team was just fantastic. Thanks Nirav, "
Atul Limited
"Nirav is an excellent Management Consultant. His company was appointed by our customer for Vendor Management Program, which included 5S and Lean Management practices. The program was quite effective. Later we engaged him for Strategic Management Program. This program is excellent and very effective. I recommend this program to companies who wants to take benefit from this.. "
Prima Automation (India) Pvt.Ltd
"I am working with greendot since last 12 + year. We are consistently improving our business process and Improved our productivity in paper mill and corrugation industries. In last couple of month we have increased our productivity by around 20% by implementing lean practice. Amazing productive experience with team greendot. They are the only consultant who can retain a client for this much duration and helping our industries to grow. "
RBR Papers LLP
"Nirav Trivedi is an excellent management consultant & coach. He and his team at Greendot has been helping multiple industries in improving productivity and reducing cost by training manpower to optimize processes and increase capacity of machines. I highly recommend his knowledge and expertise in this area. "
Accenture"We have worked with Mr Nirav Trivedi and Green Dot team for 5S implementation and journey is so good so far. 5S is not only house keeping improvement but it will help us in many other areas viz. productivity, inventory, money generation by identifying unwanted items, motivation and many more. "
Atul Limited
"Best in class Consultant for Business System development "
Shah Traders (Vapi)
"I personally Know Mr Nirav Since a Decade Now. Based on My professional experience & feedback from our a few common client of Cps Technologies & Green Dot, i can say Mr Nirav is having rich experience for management consulting in various Industry Verticles incl a working with out of India's clients, Practical approach in Problem Solving & creating A niche segment for his consulting by coaching , consulting & make client practice six sigma , lean management & etc. Techniques successfully. "
CPS Technologies
"Green Dot and NIrav Trivedi is very understanding on problems that organisation is facing and suggest remedies which suits to culture and receptiveness of employees to start off. On process improvement and setting best practices He delivers worth for company, particularly. We worked with him and satisfied with services he delivered. All the best and keep nurturing on. "
Rajhans Group of Industries
"I am enjoying with his consultation.if u want your business in automode i strongly recommend Mr Nirav Trivedi.i am in Automode r u? jaha apni soch bandh ho jati hai waha se unki soch suru hoti hai. Thank you Nirav Sir. "
Jalaram Khichdi"Most Reliable consultant, Bring our company to the next level now able to drive the company towards desire mission "
Jalaram Khichdi
"Industry specific bull's eye approach with their expertise is an effective combination in Greendot's management, for industries to upgrade their operational standards... "
Sahajanand Valves
"Nirav, has worked with our Cluster for Lean Mfg implementation. He is constantly striving for excellence in his chosen domain and working hard towards his goal to taking Green Dot to the next level. Immense clarity of thought, good methodology for implementation across wide spectrum of Industries, keeping himself abreast with latest theories. He is a good orator and a good influencer. I highly recommend Nirav to those who are seeking business solutions for the better. "
RBD Engineers Pvt Ltd
"I know Nirav for many years, he is very committed to his work and his problem solving ability is his biggest asset. He always sets very high standards for him and his team which is difficult for others to match. Wish him all the best in future! "
Firmenich
"I know Nirav ji from last 5 years and I had learned a lot from him specially how to make consistent growth in career, excellent personality with in depth knowledge Truly it was Great experience to be connected with you....Thanks for being my connection "
Pacific Group of Companies
Very happy with Greendot's services and their support in continuous development of our organization. Over an year we have not only managed to keep our inventory under control, but also improved productivity. Our profit has increased , cost has minimized and we are currently able to utilize our capacity in very efficient manner. In addition to this, we have also managed to integrate all departments through one system. Greendot team members are very professional, always supportive, polite and have helped our employees adapt to change over a short period of time. Under the guidance of Mr. Trivedi's leadership and vision Greendot success is guaranteed.
Kingsley Ecotech Pvt Ltd
Very Professional on Management !
Hebei Yitaike Bearing Co.,Ltd - ETK BearingsVery Professional on Management !
Hebei Yitaike Bearing Co.,Ltd - ETK Bearings
"He has immense and thorough knowledge of lean management, quality management system and backed by excellent academic. projects taken care by Nirajji is always hv a new experience and on time completion. "
JSW MI
"Good experience of having interacted with Mr. Nirav Trivedi. He delivered a motivational speech for undergraduate Chemical Engineering students at SCET during my tenure as Head of Chemical Engineering "
Sarvajanik College of Engineering & Technology
"Nirav is a good human being to work with and a highly professional management consultant. He has been instrumental in helping many organisations for course correction. wishing him all good things ahead. "
SEC GLOBAL CONSULTING AND INITIATIVES LLP
"Nirav has innovative thoughts and I like his management tips. "
Shreemad Rajchandra
"I would like to recommend Mr.Nirav Trivedi as a management consultant and productivity coach, Himal. "
HMC Sales
"Nirav is one of the most dynamic, versatile person i have ever came across in my professional career. He is one of the best management consultant we have in the whole Gujarat State. He has done some amazing assignments which resulted in huge cost savings , increased productivity for his clients and in some cases he along with his team managed to turn around the companies with their in depth knowledge of the subject matter. He & his team spends great amount of time to understand the root cause of the client & then they come up with the customised solution for them. I wish nirav & his team all the very best & i am sure nirav along with his team of green dot will create many more wonders in the corporate world with their expert knowledge. All the best nirav!! Keep doing the good stuff & keep helping the corporates to evolve & grow!! "
White Turtle Consulting and K&K Associate
"I was looking for an HR consulting firm and came across Nirav and his organization. Having worked with various consultants, I expected the same stuff but was pleasantly surprised to find his methods refreshingly different. Here was also a consultant who guaranteed a positive change... what could be more interesting? We are currently working with his firm and moving forward creating agents of change... Would definitely recommend him to anyone "
Vertellus Speciality Materials (India) Pvt.Ltd
"Nirav Trivedi is amazing person with great knowledge on team management and also with all the great ideas for growing own business with different tools to have faster and success. All completely solution for business for small and big business.. Amazing person with very down to earth and also ready to help everyone.. "
Imperial Overseas Education Consultants( Imperial Platforms Inc)
"I Know Nirav more the 20 years , he is Master of Management !! Keep it up "
Indobuilt Storage System Pvt.Ltd
"Superb insight in Small Business operations. Good at decoding SME bottlenecks. Polite service of the entire Organisation. Very well Read. Recommended for Management Consulting "
Usha Die Casting INDS
"Nirav & his Tem@ GreenDot Effectively Practices Trade as a Consultant to Various Small to Enterprise Organizations with ease , be it Improving Profitability, Brand Image, HR , Productivity, Efficiency & as team an asset to get associated with ! "
Matrix Network and Solutions
"Good 5s consultant "
Agarkar HR Services Pvt Ltd
"I highly recommend Mr.Nirav for his his professionalism and result oriented approach. "
Yashaswi ConsultantsWhat does a TPM consultant do?
A GreenDot TPM consultant works on your shop floor — not from a conference room. We conduct Gemba walks, attend actual breakdowns, coach operators on autonomous maintenance in real time, run weekly OEE reviews with plant leadership and facilitate focused improvement workshops on your specific equipment losses. We have implemented TPM across 100+ plants in Gujarat and India including 40 plants of Pidilite Industries — the largest multi-plant TPM engagement by any consultant in India.
What is TPM implementation?
TPM iTPM implementation is the structured deployment of Total Productive Maintenance across your production and maintenance teams. GreenDot’s TPM implementation starts with a plant
assessment and OEE baseline, moves through autonomous maintenance, planned maintenance and focused improvement, and ends only when your team can sustain results independently.
At Coptec New India Group, GreenDot’s TPM implementation delivered 45.5% production increase. At Pidilite Industries,
Which companies has GreenDot implemented TPM for in India?
GreenDot has implemented TPM and Reliability Engineering for Pidilite Industries (40 plants), Castrol, Atul Ltd, Coptec New India Group, Mcon Rasayan, Chiripal Polyfilms, Alltech Industries,
Hindustan Foods, BCI (Saudi Arabia) and 1,200+ manufacturing companies across Gujarat, Maharashtra and pan-India since 1999. No other TPM consultant in India has this breadth
of implementation experience across this many industries.
How long does TPM implementation take?
The timeframe depends on plant size, equipment condition, TPM maturity, selected pilot area and implementation scope. A practical approach normally starts with assessment and a pilot before expanding across the plant.
Can TPM be implemented in an existing manufacturing plant?
Yes. TPM can be introduced into an existing plant by assessing current equipment and maintenance practices, selecting priorities and progressively implementing appropriate TPM practices.
What is the difference between TPM and preventive maintenance?
Preventive maintenance focuses primarily on planned actions to prevent equipment failures. TPM is a broader company-wide approach that includes maintenance as well as operator involvement, focused improvement, quality, training, safety and other TPM practices.
Does GreenDot provide TPM consulting in Surat, Vadodara, Ahmedabad and across Gujarat?
Yes. GreenDot has offices in Surat and Vadodara and active,TPM engagements across all major GIDC areas — Vapi, Valsad,Bharuch, Dahej, Ankleshwar and Ahmedabad. We also serve
Maharashtra — Pune, Mumbai, Palghar, Silvassa and Daman — and deploy pan-India for large engagements. Call +91 90237 28317 to speak with a TPM consultant in your area.
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