What is Total Productive Maintenance (TPM)?

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. Total Productive Maintenance program creates a shared responsibility among stakeholders and encourages greater involvement to improve overall equipment effectiveness. Proactive engagement of operators in the equipment maintenance leads to increased employee morale and productivity, lower costs, improve quality and extend asset life.

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

  • Minimize downtime by reducing breakdowns.
  • Improve production by avoiding minor stoppages and slow running.
  • Strive for Continuous Improvement.
  • Avoid wastage by cutting down defects.
  • Reduce cost.
  • Maximize Overall Equipment Effectiveness.
  • Increase operator empowerment and participation.

Eight pillars of Total Productive Maintenance (TPM)

Total Productive Maintenance

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 of improvement.

  • Seiri (Sort): Sorting the items based on utility. Keep the items that are frequently used very close to hand, to reduce search time. Other things can be kept farther, based on their usage frequency.
  • Seiton (Systemize): Each item has a place and only one place.
  • Seiso (Shine): Keep the workplace clean, free of burrs, oil, waste, etc. Fix loose hanging wires, leakages.  Improves ability to perform.
  • Seiketsu (Standardize): Discuss and implement standards to keep the workplace enabled for maximizing production
  • Shitsuke (Sustain): Continuous efforts to ensure all the steps are performed at all times and without any gaps.

2. Autonomous Maintenance (Jishu Hozen)

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

  • Uninterrupted operation of equipment software
  • Flexible operators to operate and maintain equipment software
  • Eliminating defects at the source through active employee participation

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.

  • Practice concepts of zero losses in every sphere of activity.
  • A relentless pursuit of achieving cost reduction targets in all resources.
  • Steadfast focus to improve overall plant equipment effectiveness.
  • The comprehensive analysis to reduce/eliminate the losses.
  • Focus on the smooth handling of operators.

4. Planned Maintenance

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

  • Achieve and sustain the availability of equipment.
  • Optimize maintenance cost.
  • Reduce spares inventory.
  • Improve reliability and maintainability of equipment.

5. Quality Maintenance

The focus is on achieving and maintaining defect free products. Quality Maintenance rests on the premise that maintaining perfect equipment is essential for maintaining an ideal quality of products. Metrics are gathered and compared against standard values to institute countermeasures and prevent defects.

  • Defect-free conditions and control of equipment software.
  • Quality Maintenance activities to support quality assurance.
  • Focus on prevention of defects at the source.
  • Focus on poka-yoke. (Mistake avoidance).
  • Inline detection and segregation of defects.
  • Effective implementation of operator quality assurance.

6. Education & Training

Education & Training is provided to operators to upgrade their skill. Emphasis 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.

  • Improving the knowledge, skills, and techniques of operators.
  • Creating a training environment for self-learning based on felt needs.
  • Training curriculum/tools /assessment, etc. conducive to employee revitalization.
  • Training to remove employee fatigue and make work enjoyable.

7. Office Total Productive Maintenance (TPM)

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

  • Involvement of all employees even from support functions to focus on improving plant performance.
  • Better utilized work area.
  • Reduce repetitive work.
  • Equalizing the workload.
  • Improving the office efficiency by eliminating the time loss on retrieval of information.
  • Motion and space losses reduction. Reduce time loss in information retrieval.

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

  • Zero accident.
  • Zero physical damage.
  • Zero fires.
  • Zero pollution.

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 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 schedule. MaintWiz 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 the 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 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 providing 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.