Total Productive Maintenance – Definition, Meaning, Objectives and 8 Pillars

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Total Productive Maintenance(TPM)

Total productive maintenance is popularly known as TPM and is identified as an approach toward equipment maintenance. Its objective is to achieve one of the greatest production processes by increasing safety efficiency and productivity levels.

The emphasis of total productive maintenance is on keeping all of the gear in the best condition to reduce the possibility of breakdown and delays during the manufacturing process.

Definition of total productive maintenance

Total Productive Maintenance (TPM) is a maintenance strategy that aims to optimize the productivity and efficiency of manufacturing systems by involving all employees in the maintenance process. It is based on the principles of continuous improvement, preventative maintenance, and the involvement of all employees in equipment maintenance. The goal of TPM is to reduce downtime, improve equipment reliability, and increase overall productivity and efficiency. TPM involves a data-driven approach, using metrics and data to make informed decisions about maintenance procedures and priorities. The focus is on maximizing the performance and efficiency of equipment while minimizing the need for corrective maintenance.

Objectives

Goals of total productive maintenance

  1. Increased Equipment Efficiency: TPM aims to optimize the performance and efficiency of equipment, reducing downtime and maximizing productivity.
  2. Improved Equipment Reliability: TPM emphasizes preventative maintenance, reducing the frequency and severity of equipment failures.
  3. Enhanced Employee Involvement: TPM encourages the involvement of all employees in the maintenance process, including production workers, to increase overall efficiency and productivity.
  4. Continuous Improvement: TPM is a continuous improvement process that regularly reviews and updates maintenance procedures to ensure maximum efficiency.
  5. Cost Reduction: TPM aims to reduce maintenance costs by preventing equipment failures and reducing the need for corrective maintenance.
  6. Increased Safety: TPM emphasizes safe and effective maintenance procedures, reducing the risk of accidents and incidents.
  7. Data-Driven Decision Making: TPM utilizes data and metrics to make informed decisions about maintenance procedures and priorities, improving the overall efficiency of the maintenance process.

Key features of Total Productive Maintenance (TPM)

The key features of Total Productive Maintenance (TPM) are:

  1. Involvement of All Employees: TPM involves all employees in the maintenance process, from production workers to management, to increase overall efficiency and productivity.
  2. Focus on Equipment Efficiency: TPM prioritizes the maintenance of equipment in order to maximize its efficiency and productivity.
  3. Preventative Maintenance: TPM places a strong emphasis on preventative maintenance, reducing the frequency and severity of equipment failures and minimizing the need for corrective maintenance.
  4. Continuous Improvement: TPM is a continuous improvement process, regularly reviewing and updating maintenance procedures to ensure maximum efficiency.
  5. Data-Driven Decision Making: TPM uses data and metrics to make informed decisions about maintenance procedures and priorities, improving the overall efficiency of the maintenance process.
  6. Total Quality Management: TPM incorporates Total Quality Management (TQM) principles to continuously improve the quality of the maintenance process.
  7. Employee Training: TPM includes training programs for all employees to ensure they have the necessary skills and knowledge to effectively participate in the maintenance process.
  8. Metrics-Driven: TPM utilizes a variety of metrics, such as Overall Equipment Effectiveness (OEE), to measure the effectiveness of the maintenance process and to identify areas for improvement.

Eight pillars of total productive maintenance(TPM)

tpm Total Productive Maintenance

The eight pillars of Total Productive Maintenance (TPM) are:

1. Autonomous Maintenance

Involves production workers in the maintenance process to increase equipment reliability and reduce downtime.

Autonomous Maintenance is one of the eight pillars of Total Productive Maintenance (TPM). It involves production workers in the maintenance process to increase equipment reliability and reduce downtime.

The goal of Autonomous Maintenance is to empower production workers to take ownership of the equipment they use, by performing simple maintenance tasks such as cleaning, lubricating, and checking equipment regularly. This helps to reduce the frequency and severity of equipment failures, as well as increase the overall efficiency and productivity of the equipment.

Autonomous Maintenance also helps to promote a culture of continuous improvement, as production workers are more likely to identify and report problems with the equipment they use on a regular basis. This information can then be used to improve the maintenance process, reducing the need for corrective maintenance and maximizing the efficiency of the equipment.

Autonomous Maintenance is a critical component of TPM, as it encourages the involvement of all employees in the maintenance process, ultimately contributing to the overall success of the organization. By implementing Autonomous Maintenance, organizations can improve equipment reliability, reduce downtime, and increase overall productivity and efficiency.

2. Focused Improvement

A structured approach to continuous improvement that targets specific areas for improvement.

Focused Improvement is one of the eight pillars of Total Productive Maintenance (TPM). It refers to a structured approach to continuous improvement that targets specific areas for improvement. The goal of Focused Improvement is to increase equipment efficiency, improve equipment reliability, and reduce maintenance costs.

Focused Improvement is based on the principle of continuous improvement, where teams work together to identify and eliminate waste in the production process. The process involves analyzing data and metrics to identify areas for improvement, setting specific improvement goals, and implementing improvement plans to achieve those goals. Focused Improvement is an ongoing process that involves regular review and updates to ensure maximum efficiency.

Focused Improvement is a critical component of TPM, as it helps organizations to continuously improve their equipment and processes. By implementing Focused Improvement, organizations can reduce downtime, improve equipment reliability, and increase overall productivity and efficiency.

3. Planned Maintenance

A preventive maintenance program that focuses on regular maintenance to reduce the frequency and severity of equipment failures.

Planned Maintenance is one of the eight pillars of Total Productive Maintenance (TPM). It refers to a preventive maintenance program that focuses on regular maintenance to reduce the frequency and severity of equipment failures.

The goal of Planned Maintenance is to ensure that equipment is maintained in optimal condition, reducing the need for corrective maintenance and maximizing the efficiency of the equipment. This is achieved by scheduling regular maintenance activities, such as cleaning, lubricating, and checking equipment, to prevent potential problems from becoming serious issues.

Planned Maintenance is based on the principle of preventative maintenance, where maintenance is performed regularly to prevent equipment failures. This helps to minimize the need for corrective maintenance, reducing downtime and improving equipment reliability.

Planned Maintenance is a critical component of TPM, as it helps organizations to proactively maintain their equipment, reducing the need for corrective maintenance and maximizing the efficiency of the equipment. By implementing Planned Maintenance, organizations can improve equipment reliability, reduce downtime, and increase overall productivity and efficiency.

4. Quality Maintenance

A focus on maintaining the quality of equipment and production processes to ensure consistent and reliable performance.

Quality Maintenance is one of the eight pillars of Total Productive Maintenance (TPM). It refers to a focus on maintaining the quality of equipment and production processes to ensure consistent and reliable performance.

The goal of Quality Maintenance is to ensure that equipment is operating at its maximum potential, producing high-quality products that meet customer requirements. This is achieved by implementing quality control measures, such as regular equipment inspections, to detect and correct any quality problems early on.

Quality Maintenance also involves the use of data and metrics to monitor equipment performance and identify areas for improvement. This information can then be used to implement improvements to the equipment and production processes, resulting in increased efficiency and reliability.

Quality Maintenance is a critical component of TPM, as it helps organizations to ensure the quality of their products and processes, improving customer satisfaction and contributing to the overall success of the organization. By implementing Quality Maintenance, organizations can improve equipment reliability, reduce downtime, and increase overall productivity and efficiency.

5. Training and Education

A training program for all employees to ensure they have the necessary skills and knowledge to effectively participate in the maintenance process.

Training and Education are one of the eight pillars of Total Productive Maintenance (TPM). It refers to a training program for all employees to ensure they have the necessary skills and knowledge to effectively participate in the maintenance process.

The goal of Training and Education is to ensure that all employees understand the importance of maintenance and the role they play in maintaining equipment reliability. This is achieved by providing regular training sessions, such as on-the-job training, to familiarize employees with the maintenance process and improve their maintenance skills.

Training and Education are also important for promoting a culture of continuous improvement, as employees are more likely to identify and report problems with the equipment they use if they have a good understanding of how it works.

Training and Education is a critical component of TPM, as it ensures that all employees have the necessary skills and knowledge to effectively participate in the maintenance process. By implementing Training and Education, organizations can improve equipment reliability, reduce downtime, and increase overall productivity and efficiency.

6. Early Equipment Management

A proactive approach to equipment management involves identifying and addressing potential problems before they become serious issues.

Early Equipment Management (EEM) is one of the eight pillars of Total Productive Maintenance (TPM). It refers to a proactive approach to equipment management that focuses on reducing the need for corrective maintenance.

The goal of EEM is to ensure that equipment is designed, manufactured, and maintained in a manner that reduces the need for corrective maintenance and maximizes the efficiency of the equipment. This is achieved by considering the maintenance requirements of equipment during the design and manufacturing process, and by implementing maintenance programs that proactively address potential problems before they become serious issues.

EEM also involves regular monitoring and analysis of equipment performance, to identify areas for improvement and implement changes to the equipment or maintenance processes. This helps to reduce downtime, improve equipment reliability, and increase overall productivity and efficiency.

EEM is a critical component of TPM, as it helps organizations to proactively manage their equipment, reducing the need for corrective maintenance and maximizing the efficiency of the equipment. By implementing EEM, organizations can improve equipment reliability, reduce downtime, and increase overall productivity and efficiency.

7. Health, Safety, and Environmental Protection

A focus on maintaining a safe and healthy work environment, as well as protecting the environment.

Health, Safety, and Environmental Protection (HSE) is one of the eight pillars of Total Productive Maintenance (TPM). It refers to a focus on maintaining a safe and healthy work environment, while also protecting the environment.

The goal of HSE is to ensure that all employees are working in a safe and healthy environment and that the organization is in compliance with all relevant health, safety, and environmental regulations. This is achieved by implementing a comprehensive health and safety program, as well as an environmental management system, to identify and manage potential risks to the health and safety of employees, as well as to the environment.

HSE is also important for promoting a culture of continuous improvement, as employees are more likely to identify and report potential health, safety, and environmental risks if they are aware of the importance of these issues.

HSE is a critical component of Total Productive Maintenance (TPM), as it ensures that all employees are working in a safe and healthy environment and that the organization is in compliance with all relevant health, safety, and environmental regulations. By implementing HSE, organizations can improve equipment reliability, reduce downtime, and increase overall productivity and efficiency, while also contributing to a safer and healthier work environment.

8. Office TPM

The application of TPM principles to office operations, including the use of metrics and data to drive improvement.

Office TPM, also known as Total Productive Office Maintenance, is an extension of the Total Productive Maintenance (TPM) philosophy and methodology, applied to office and administrative processes.

The goal of Office TPM is to improve the productivity, efficiency, and quality of office and administrative processes, just as TPM does for manufacturing processes. It involves involving all office employees in the continuous improvement of office processes and procedures, using the same 8 pillars of Total Productive Maintenance (TPM) (Autonomous Maintenance, Planned Maintenance, etc.) to improve the way work is done.

Office TPM applies TPM principles to administrative tasks, such as data management, document control, and communication processes, to increase efficiency and reduce waste. It also involves training and educating employees on the principles of Total Productive Maintenance (TPM) and how they can be applied to their work, and implementing regular audits and assessments of office processes to identify areas for improvement.

By implementing Office TPM, organizations can improve the efficiency and effectiveness of their administrative processes, reducing waste, increasing productivity, and providing a higher level of customer service. This, in turn, contributes to the overall success of the organization.

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OEE and the 6 major losses

OEE, or Overall Equipment Effectiveness, is a metric used to measure the efficiency and effectiveness of a manufacturing process. It takes into account all of the factors that contribute to production losses and provides a single overall score for the process.

The 6 major losses that impact OEE are:

  1. Availability Loss: This loss occurs due to scheduled and unscheduled downtime, such as maintenance, equipment breakdowns, and process changes.
  2. Performance Loss: This loss occurs when the equipment is running, but not at its maximum capacity, due to factors such as improper set-up, worn-out equipment, or operator errors.
  3. Quality Loss: This loss occurs when products are produced that do not meet the required quality standards, due to factors such as incorrect settings, operator error, or equipment failure.
  4. Speed Loss: This loss occurs when the equipment runs slower than its maximum possible speed, due to factors such as slow changeovers, equipment limitations, or inadequate maintenance.
  5. Yield Loss: This loss occurs when raw materials are wasted, or products are discarded because they do not meet quality standards.
  6. Startup Loss: This loss occurs during the start-up of a process when there is a loss of production due to factors such as equipment calibration, material preparation, or personnel training.

By identifying and addressing these 6 major losses, organizations can improve their OEE score and increase their overall efficiency and effectiveness. Total Productive Maintenance (TPM), with its focus on continuous improvement, provides a framework for identifying and reducing these losses and improving the OEE of a manufacturing process.

OEE Score Industrial aspects

A score of 100 % OEE is termed a perfect production
A score of 85e % OEE is termed as world-class for discrete manufacturers
A score of 60% OEE is termed typical for discrete manufacturers
A score of 40 % OEE is termed as one with no lean programs or Total Productive Maintenance (TPM)

Total productive maintenance benefits(TPM)

  1. Improved Equipment Reliability: TPM focuses on involving all employees in the maintenance and improvement of equipment, leading to increased equipment reliability and reduced downtime.
  2. Increased Productivity: By reducing downtime and improving the efficiency of equipment, TPM increases overall productivity and reduces waste.
  3. Improved Quality: TPM places a strong emphasis on quality maintenance and involves all employees in quality improvement initiatives, leading to improved product quality and reduced defects.
  4. Increased Employee Involvement: TPM involves all employees in the improvement of equipment, processes, and procedures, leading to increased employee involvement and commitment.
  5. Improved Safety: TPM places a strong emphasis on health, safety, and environmental protection, leading to improved working conditions and reduced workplace accidents.
  6. Increased Cost Savings: TPM reduces waste, improves equipment reliability, and increases overall efficiency, leading to significant cost savings for the organization.
  7. Improved Customer Satisfaction: By improving the quality of products and reducing downtime, TPM contributes to improved customer satisfaction and increased customer loyalty.
  8. Continuous Improvement Culture: TPM provides a framework for continuous improvement and involves all employees in the improvement of equipment, processes, and procedures, leading to a culture of continuous improvement within the organization.

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