What is TPM (Total Productive Maintenance)?

Total Productive Maintenance (TPM) focuses on getting managers, maintenance personnel and equipment users all working together to prevent equipment problems and reduce expenditures. By giving ownership and responsibility of equipment and processes to the right employee, equipment breakdowns are reduced. 5S provides a systematic approach to setting standards and visual guides for preventing breakdowns and making your equipment run smoothly.

TPM aims at:

1. Makes “Lean-Production” and “JIT” possible.
2. Improve “Cross Functional Working” by eliminating departmental interruption.
3. Improve “Overall Equipment Problems”.
4. Makes possible “Man less Operation”, “Factory Operation”.
5. Reinforce people and facilities, resulting in energize organisation,
6. Restructuring the corporate culture through improvement of human resources and equipments.
7. Creates a blazing, clean, amiable company.

TPM have three basic goals:

  1. Zero Product Defects,
    2. Zero Equipment Failures and
    3. Zero Accidents.

These goals are achieved by Gap Analysis of previous records of product defects including customer complaints, equipment failures and accidents. Gap Analysis clearly understands by the Cause Effect Analysis, Why-Why Analysis and P-M Analysis and other tools are used to plan a physical investigation to discover the weak areas.
TPM has Eight pillars of activity, each being set to achieve a “zero” targets.
These eight pillars are:
1. Focussed improvement (Kobetsu Kaizen),
2. Autonomous Maintenance (Jishu Hozen),
3. Planned Maintenance,
4. Training and Education,
5. Early phase Management,
6. Quality Maintenance (Hinshitsu Hozen),
7. Office TPM,
8. Safety, Health and Environment.

TPM is a holistic approach to equipment maintenance that strives to achieve perfect production:
a. No Breakdowns
b. No Small Stops or Slow Running
c. No Defects

In addition it values a safe working environment:

  1. a. No Accidents
    TPM emphasizes proactive and preventive 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.
    The implementation of a TPM program creates a shared responsibility for equipment that encourages greater involvement by plant floor workers. In the right environment this can be very effective in improving productivity (increasing up time, reducing cycle times and eliminating defects).

This Training Enables Learners To:

1. Explain how TPM aids lean efforts and addresses wastes.
2. Know the difference between Corrective Maintenance (CM), Preventive Maintenance (PM) and Predictive Maintenance (PdM).
3. Understand how the three sequential phases of TPM build on each other.
4. Realize how PdM techniques can further traditional PM practices.