Total Productive Maintenance is a holistic approach to equipment maintenance to achieve the goal of zero defects, zero breakdowns, and zero accidents. TPM emphasizes on empowerment of operators to work in a concerted manner to ensure optimal performance of equipment maintenance. The Total Productive Maintenance program creates a shared responsibility among stakeholders and encourages greater involvement to improve overall equipment effectiveness. Proactive engagement of operators in equipment maintenance leads to increased employee morale and productivity, lower costs, and improved quality and extended asset life.

What are the Objectives of Total Productive Maintenance (TPM)?

Eight pillars of Total Productive Maintenance (TPM)

1. Early Management

TPM Manufacturing starts with 5S. Problems are not visible when the workplace is unorganized. Cleaning and organizing the workplace helps the team to find out the underlying problems easily. Making issues visible is the first step toward improvement.

2. Autonomous Maintenance (Jishu Hozen)

Jishu Hozen focuses on developing operators to be able to take care of small maintenance tasks, freeing up a skilled maintenance software team. Operators are responsible for the upkeep of their equipment to prevent it from deteriorating.

3. Focused Improvement (Kobetsu Kaizen)

Kaizen is for small improvements carried out on a continuous basis, as against dramatic changes.  Kobetsu Kaizen aims at reducing losses in the workplace.

4. Planned Maintenance

To focus on preventive actions to eliminate equipment failures/breakdowns to ensure the availability and reliability of equipment and minimize the cost of CMMS maintenance software. With Planned Maintenance, the focus is to evolve from reactive to proactive maintenance.

5. Quality Maintenance

Jishu Hozen focuses on developing operators to be able to take care of small maintenance tasks, freeing up a skilled maintenance software team. Operators are responsible for the upkeep of their equipment to prevent it from deteriorating.

6. Education & Training

Education & Training is provided to operators to upgrade their skill. Emphasis is placed on not only knowing “Know-How” but also on knowing “Know-Why.” The objective is to have multi-skilled employees who are eager to come to work and perform all required functions efficiently and independently.

7. Office Total Productive Maintenance (TPM)

Office TPM focuses on improving productivity and efficiency in the administrative functions to enable the identification and elimination of losses.

8. Safety, Health & Environment

The focus is to create a safe workplace and surrounding areas, by eliminating potential safety and health risks. The center is on ensuring

How can MaintWiz help in achieving TPM Excellence?

1. Overall Equipment Effectiveness (OEE): Automate the computation of OEE at the Equipment, Line or Plant level. Monitor the 16 losses. Improve performance and production quality.

2. Downtime Countermeasures: Track breakdowns, root cause analysis (why Why analysis) and apply countermeasures. Help focus on increasing Mean Time Between Failures (MTBF) and reducing the mean time to repair (MTTR). Horizontal deployment to avoid losses in similar equipment.

3. Preventive Maintenance Program: Develop the schedule of PM activities and track conformance to the schedule. MaintWiz CMMS software supports Time Based Maintenance (TBM), Condition Based Maintenance (CBM) and Event-Based Maintenance (EBM) to meet your differing needs.

Establish CLITA (Cleaning-Lubrication-Inspection-Tightening-Adjustment) Standards. Schedule CLITA activities and monitor compliance.

4. Spare Parts Management: Establish inventory standards and minimum stock levels for parts needed on a Planned basis.

5. Maintenance Cost Analysis: Get compelling insights on the Total Cost of Maintenance – broken up by Spare Parts, Labour and Vendor costs. Categorize them based on the breakdown of maintenance and preventive maintenance costs. View Equipment level cost of maintenance and monthly trends.

6. Maintenance Efficiency Improvement: Track maintenance activities by category: planned (time-based, condition-based, predictive), and unplanned (breakdown maintenance). Focus on improving the percentage of maintenance hours on planned vs. unplanned activities. Reduce overall cost of maintenance.

7. Support and Guidance for Operator Self-Maintenance: Program to systematically enhance maintenance team technical skills. Many organizations have adopted efficiently One Point Lessons (OPL) and provided instructions for operators via CMMS.

8. TPM Preparedness: Identify and monitor TPM goals on a daily basis. Dashboard measures the key performance indicators to bubble up to the problem areas that require improvement. Achieve TPM Excellence and sustain the momentum.

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