Total Productive Maintenance (TPM)

What is Total Productive Maintenance (TPM) and how will it help my workplace?

Total Productive Maintenance (TPM) is a maintenance program which involves a newly defined concept for maintaining plants and equipment. The aim of TPM is to increase production while concurrently increasing employee morale and job satisfaction.

TPM considers maintenance as a vital aspect of the business, ensuring it is no longer regarded as a non-profit activity. Downtime 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 keep emergency and unscheduled maintenance to a minimum.

Step 1 (includes preparation)

  • Learn the tools and techniques of Planned Maintenance
  • Understand the 7 steps of Planned Maintenance (ref. Japan Institute of Planned Maintenance)
  • Apply Step 1 of Planned Maintenance at your workplace

Key Points / Outcomes:Pillars of TPM

  • Line of sight PM board
  • Team formation
  • Master Plan eneration
  • MTBF
  • MTBA
  • MTTR
  • OEE
  • A-tagging
  • Planned maintenance
  • Maintenance
  • Minor restoration
  • One Point Lesson
  • Kanban systems
  • Workplace
    Organisation (WPO)

Step 2 and 3 (includes workshop)

  • Countermeasures (based on Equipment Failure Map)
  • Why-Why analysis
  • Zero component/equipment failure due to forced deterioration
  • Identify and determine Cleaning, Inspection
    and Lubrication (CIL) checkpoints
  • Incorporate functional machine cleaning into Autonomous Maintenance (AM) operating procedures
  • Understand and implement Visual Control Systems (ACS)

Key Points / Outcomes:

  • 5 Failure Factors
  • Why-Why Analysis Tool knowledge Documentation
  • Team assessment
  • Understanding equipment and its components intimately

Total Productive Maintenance (TPM) is a methodology for ensuring optimal machine performance.

Machines tend to make up a significant portion of business processes. As a result, the performance of these machines are incredibly important to the efficiency and effectiveness of the business.

The machine wastes caused by poor machine performance are:

  • Breakdowns
  • Changeovers
  • Idling and minor stoppages
  • Speed losses
  • Quality defects and rework
  • Start-up and reduced yield

Most organisations are well aware of these wastes but are under the false impression that these factors come naturally when working with machines. This is incorrect, hence the goal behind implementing TPM.

Overall Equipment Effectiveness (OEE) is an accurate way of measuring the performance of equipment.

Developing an OEE metric should be a primary step as it will allow you to measure your current TPM performance. OEE takes into account all machine wastes and is constructed from:

  • The availability of a machine
  • The performance level of a machine
  • The quality level of a machine

In a highly effective workplace that practices Total Productive Maintenance, downtime for maintenance is scheduled as a part of the manufacturing day and, in some cases, as an integral part of the manufacturing process. Operators are trained in visually checking equipment and identifying problems and often perform basic preventative maintenance tasks. TPM states that emergency and unscheduled maintenance should be kept to a minimum. This will ensure a smooth and predictable manufacturing system.

There are 7 steps to implement Total Productive Maintenance, which provide a structured methodology to reduce your machine waste. As you implement TPM, you should see an improvement in your Overall Equipment Effectiveness (OEE):

  • Perform initial machine cleaning and inspection
  • Repair machine defects and leaks
  • Develop Operator and Maintenance PM schedules
  • PM activity performed by the Operator
  • PM activity performed by the Maintenance Personnel
  • Build 5S system for all machines
  • Monitor OEE and set improving goals & actions

Download Our Free PDF to learn more about Total Productive Maintenance (TPM). Contact us to find out how we can help you implement Total Productive Maintenance (TPM) to help you achieve your business improvement goals.

Download our PDF to learn more about Total Productive Maintenance (TPM)