Unlocking the Benefits of Total Productive Maintenance (TPM)

Total Productive Maintenance (TPM) is a process that involves machines, equipment, employees and supporting processes. It aims to maintain and improve production efficiency and system quality. It emphasizes proactive and preventive maintenance techniques to achieve perfect production and maximum equipment effectiveness.

By empowering operators to maintain their equipment, TPM fosters shared responsibility for equipment, encouraging heightened participation from plant floor workers.

TPM Origins

The roots of TPM can be traced back to Japan, where companies like Toyota were among the first to receive TPM certification. The underlying philosophy of TPM is that "TPM is the creation of products through the development of individuals."

With the rise in automation and the abundance of automated production lines, the concept of autonomous maintenance emerged, equipping machine operators with the capability to carry out maintenance work independently. The 5 steps of workplace organization—sort, arrange, shine, standardize and sustain —lay the foundation for TPM.

Key Principles of TPM

The fundamentals of Total Productive Maintenance (TPM) are based on eight core pillars. These include:

1. Autonomous maintenance
2. Focused improvement (also called ‘Kaizen’)
3. Planned maintenance
4. Quality management
5. Early equipment management
6. Training and education
7. TPM in an office environment
8. SHE (safety, health, education) considerations 

The objective of TPM is to reach zero breakdowns, zero defects, zero accidents and maximum efficiency and availability of manufacturing equipment.

Overall Equipment Effectiveness (OEE) plays a critical role in TPM as a key performance indicator (KPI) for maintenance, assessing the production level of an asset based on availability, performance and quality. OEE is a fundamental part of Total Productive Maintenance (TPM). It enables the assessment of desired targets, such as achieving no breakdowns (availability), avoiding small stops or slow running (performance) and preventing defects (quality).

By implementing preventive maintenance tasks and engaging machine operators in maintenance operations, TPM reaps numerous benefits.

Components of OEE

OEE is a comprehensive metric that combines availability, performance and quality to assess the overall effectiveness of equipment. Availability is determined by taking into account the time lost due to equipment malfunction, setup and adjustment time, as well as beginning work after breaks and weekends. This is all deducted from 100 percent. Performance calculation considers the time lost due to minor interruptions. It also accounts for the difference between the actual speed and the optimal speed. Quality is a measure of efficiency and performance. It is calculated by subtracting losses owing to production-related issues from 100 percent.

Tracking and Improving OEE

OEE tracking and improvement can be achieved through manual calculations or automated software, with data collected for a minimum of two weeks to accurately represent unplanned stoppage time. A 100 percent OEE indicates that all products produced are of the highest quality, production is optimized for maximum speed and there is no unexpected downtime. By involving machine operators in maintenance activities, TPM allows improvement measures to be implemented at the point of action and seamlessly integrated into the continuous improvement process.

The eight pillars of TPM are centered around proactive and preventative approaches to enhancing equipment dependability, forming a solid foundation for improved equipment performance and reliability. Emphasizing autonomous maintenance, focused improvement (Kaizen), planned maintenance, quality management, early equipment management, training and education, TPM in an office environment and safety, health and environmental (SHE) considerations, TPM aims to achieve zero breakdowns, zero defects and zero accidents.

TPM is a holistic approach to equipment maintenance that seeks to engage all members of an organization in the maintenance process. It encourages employees to take ownership of their equipment and to be proactive in identifying and addressing potential problems. 

1. Autonomous Maintenance

Autonomous maintenance, the second field of action of TPM, stipulates that minor maintenance, inspection, cleaning and lubrication tasks are to be carried out by the machine operator rather than specialized technicians. This practice reduces downtime, enhances safety and optimizes the productivity of the production process, ultimately resulting in lower maintenance costs and extended machine lifespan.

Implementing autonomous maintenance involves training operators in the technical skills necessary for conducting routine inspections and maintaining a "baseline" standard of cleanliness.

2. Focused Improvement (Kaizen)

Focused improvement, or Kaizen, is the first pillar of TPM and a structured, team-based approach to systematically eliminate identified losses in any process. By encouraging continuous improvement and collaboration among teams, Kaizen promotes identifying and eliminating losses in any process, thereby enhancing productivity, quality and safety.
This philosophy is based on the Japanese concept of Kaizen, which emphasizes gradual, methodical improvement through cross-functional problem-solving approaches.

3. Planned Maintenance

Planned maintenance—a proactive approach to maintenance management—involves planning, documenting and scheduling maintenance activities in advance to reduce downtime and prevent equipment failure. In TPM, planned maintenance facilitates inventory buildup in anticipation of scheduled maintenance activities, helping to reduce any production disruptions caused by these activities. Planned maintenance in TPM is based on failure-rate datasets, offering numerous benefits.

4. Quality Maintenance

Quality maintenance in TPM emphasizes the implementation of measures to maintain and enhance the quality of products and the reliability of processes. The objective of quality maintenance is to identify potential issues that could disrupt zero-defect production. This ensures the highest possible standards of quality are maintained. Quality maintenance tasks include establishing quality standards, implementing systems to identify defects and errors early, performing trend analyses, putting systems in place to prevent defects and errors and implementing a quality management matrix.

5. Early Equipment Management

Early Equipment Management (EEM) is a structured process designed to reduce complexity related to the real-time operation and maintenance of equipment. As a TPM pillar, EEM connects the manufacturing and commercial goals of an organization to leverage the foundation established through standardized processes. EEM offers numerous advantages, including enhanced equipment reliability, heightened production efficiency, minimized downtime and increased safety. However, challenges associated with EEM include comprehending the equipment comprehensively, developing a well-defined maintenance strategy and ensuring a well-trained workforce.

6. Training and Education

Training and education are essential in TPM to guarantee that personnel possess the requisite knowledge and abilities to execute TPM proficiently. The training imparts specific skills, while education involves theoretical learning in a classroom or institution. Various training and education methods are available, including classroom instruction, on-the-job training, online courses and seminars. Training and education in TPM can assist personnel in comprehending the fundamentals of TPM, cultivating the required abilities to apply TPM and amplifying their overall efficiency.

7. TPM in an Office Environment

TPM has a wide scope; it not only focuses on production facilities but also enhances office and administrative operations. Its objective is to improve overall efficiency and effectiveness. TPM in an office environment can provide improved efficiency, increased quality and optimized equipment effectiveness. TPM is a key component of this philosophy, striving to maximize equipment effectiveness, optimize efficiency and guarantee quality in all aspects of office operations.

8. Safety, Health and Environment (SHE)

Work Safety, Health and Environmental Protection in TPM aims to guarantee a secure and healthy work environment and safeguard the environment. Raising awareness among individual employees is crucial for creating a corporate culture in which productivity within manufacturing and all related functional areas is continually improved.
Training employees in the eighth field of action of TPM helps them recognize potential hazards in work safety, health and environmental protection and take preventative measures on time. The primary focus of TPM is to provide a safe and secure environment for all personnel.

Implementing TPM involves a series of steps, starting with selecting a pilot area and progressing through restoring equipment to prime operating condition, measuring OEE and addressing major losses and finally introducing proactive maintenance techniques.
By following these steps organizations can successfully implement TPM and reap its numerous benefits, including improved equipment performance, reliability and overall productivity.

Identify Pilot Area

The first step in initiating TPM is identifying a pilot area, a crucial stage that sets the foundation for the entire implementation process. Involving employees in the pilot selection process is essential for gaining greater acceptance from staff and ensuring a successful implementation.

Factors to consider when selecting equipment for a pilot area include whether the equipment is easily upgradable, a potential bottleneck and if downtime can be tolerated. A visual project board can showcase progress for all stakeholders and keep everyone informed and engaged.

Restore Equipment to Prime Operating Condition

Restoring equipment to its optimal functioning state is a vital component of TPM and is usually the second step in the implementation process. This process entails cleaning, lubricating and replacing components, in addition to determining and resolving the source of the issue.

Restoring equipment to its optimal operating condition offers numerous advantages, including enhanced equipment dependability, augmented production efficacy and minimized maintenance expenses.

Measure OEE and Address Major Losses

Measuring OEE, a key performance indicator in TPM and addressing major losses are integral steps in the implementation process. By categorizing every unplanned stoppage event, it is possible to gain a more precise understanding of where a stoppage is occurring and identify and address major losses. Tracking and monitoring OEE can be achieved through manual calculations or automated software, ensuring accuracy by collecting data for a minimum of two weeks.

Introduce Proactive Maintenance Techniques

The concluding step in the TPM process is incorporating proactive maintenance techniques, such as condition-based, predictive and preventive maintenance, into the maintenance program. To initiate proactive maintenance, it is essential to identify components suitable for proactive maintenance, set up initial proactive maintenance intervals and develop a feedback system for optimizing maintenance intervals.

Introducing these techniques can help organizations enhance their equipment performance, reliability and overall productivity.

Sustaining TPM success requires continuous improvement, employee training and management commitment. Engaging leadership demonstrates the importance of the program through tangible actions and discourages employees from reverting to former practices. Employee engagement fosters a strong sense of unity and acknowledges accomplishments.

Utilizing digital TPM software for providing preventive maintenance plans, all-in-one document management and autonomous maintenance checklists with multimedia instructions can aid in sustaining TPM success.

Total Productive Maintenance is a powerful lean management strategy that, when implemented and sustained effectively, can transform an organization's performance by optimizing facility maintenance and eliminating waste, accidents, defects and downtime.

By understanding the key principles of TPM, measuring and improving OEE, embracing the eight pillars of TPM and following the steps for implementation organizations can unlock the benefits of TPM and achieve a competitive edge in today's fast-paced manufacturing landscape. Embrace the power of TPM and embark on a journey of continuous improvement, productivity and success.

Total Productive Maintenance is a powerful lean management strategy that, when implemented and sustained effectively, can transform an organization's performance by optimizing facility maintenance and eliminating waste, accidents, defects and downtime.

By understanding the key principles of TPM, measuring and improving OEE, embracing the eight pillars of TPM and following the steps for implementation, organizations can unlock the benefits of TPM and achieve a competitive edge in today's fast-paced manufacturing landscape. Embrace the power of TPM and embark on a journey of continuous improvement and enhanced productivity.