What is TPM

TPM (Total Productive Maintenance) is a holistic approach to equipment maintenance that strives to achieve perfect production:

  • No Breakdowns
  • No Small Stops or Slow Running
  • No Defects

In addition, it values a safe working environment:

  • No Accidents

TPM emphasizes proactive and preventative maintenance to maximize the operational efficiency of equipment. It blurs the distinction between the roles of production and maintenance by placing a strong emphasis on empowering operators to help maintain their equipment.

Eight Pillars of TPM

  • Autonomous Maintenance
  • Individual Improvement
  • Planned Maintenance
  • Quality Maintenance
  • Education and Training
  • Safety Health and Environment
  • Office Management
  • Development Management

The eight pillars of TPM are mostly on proactive and preventive techniques for improving equipment reliability.

Eight Pillar  ObjectivesAdvantages
Autonomous MaintenancePlaces responsibility for routine maintenance, such as cleaning, lubricating and inspection in the hands of operatorsGives operators greater “ownership” of their equipment.Increases operator’s knowledge of their equipment.Ensures equipment is well-cleaned and lubricated.Identifies emergent issues before they become failures.Frees maintenance personnel for higher- level tasks.
Individual /Focussed Improvement  Focused improvement is the initial pillar of total productive maintenance system, it is focus on improvement on the whole system, through identify and eliminate losses by team approach. Organizational complex issues can possible through implementation of focused improvement step.Reduces lead time to new product launch Reduce the losses Cost Effective    
Planned MaintenanceSchedules maintenance tasks based on predicted and/or measured failure ratesSignificantly reduces instances of unplanned stop time. Enables most maintenance to be planned for times when equipment is not scheduled for production. Reduces inventory through better control of wear-prone and failure-prone parts
Quality MaintenanceDesign error detection and prevention into production processes. Apply Root Cause Analysis to eliminate recurring sources of quality defects.Specifically targets quality issues with improvement projects focused on removing root sources of defects. Reduces number of defects Reduces cost by catching defects early (it is expensive and unreliable to find defects through inspection)
Education and Training  Fill in knowledge gaps necessary to achieve TPM goals. Applies to operators, maintenance personnel and managers.Operators develop skills to routinely maintain equipment and identify emerging problems. Maintenance personnel learn techniques for proactive and preventative maintenance. Managers are trained on TPM principles as well as on employee coaching and development
Safety Health and Environment  Maintain a safe and healthy working environment.Eliminates potential health and safety risks, resulting in a safer workplace. Specifically targets the goal of an accident-free workplace.
Office ManagementApply TPM techniques to administrative functions.Extends TPM benefits beyond the plant floor by addressing waste in administrative functions. Supports production through improved administrative operations (e.g. order processing, procurement, and scheduling).
Development ManagementThis pillar aimed towards • Collection & utilization of feedback information regarding present products before the start of the design. • Measuring needs for “easy of manufacturing “by analyzing the process for present products. • Measuring needs for “easy of manufacturing” by analyzing process of new products in the stage of planning & design of products.  – By identifying failures possibilities based on design reviews of new products. – By identifying failures possibilities based on trial manufacturing & test of new products Benefits   Reduces lead time to new product launch Reduce the losses Cost Effective

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