TPM consulting and training

1. What is TPM?

TPM stands for Total Productive Maintenance.

It is an approach to maintaining and improving production-system effectiveness, safety and quality through the management of equipment, processes and people.

TPM aims to keep equipment in suitable operating condition and prevent breakdowns, delays and other production losses.

2. History of TPM

Seiichi Nakajima played a major role in developing TPM through Japanese maintenance practice during the period from the 1950s to the 1970s. Experience showed that leadership involvement and small-group improvement were essential to effective implementation.

JIPM identifies 1971 as the year TPM was proposed and DENSO received the TPM Award. The approach developed through cooperation between industry and JIPM, the Japan Institute of Plant Maintenance. Seiichi Nakajima is widely associated with its development.

TPM evolved from an equipment-maintenance focus towards company-wide participation, commonly organised around eight pillars.

3. TPM objectives

TPM improves equipment effectiveness by involving people who influence its performance in small-group improvement. It complements wider quality-management activities and needs commitment across the workforce. Intended benefits include better output, employee engagement and job satisfaction.

A central objective is to improve Overall Equipment Effectiveness, or OEE. TPM addresses the causes of deterioration and develops an effective relationship between operators, maintenance personnel and equipment.

OEE has three factors: Performance, Availability and Quality.

OEE formula

OEE = Performance × Availability × Quality.

Each factor is associated with two major losses, giving six big losses overall:

Performance losses: reduced speed and minor stops.

Availability losses: breakdowns and product changeovers or setup.

Quality losses: startup rejects and rejects during normal production.

Teams identify, prioritise and address the causes of these losses. Employee participation helps establish the ownership and problem-solving culture needed to sustain the changes.

4. The pillars of TPM

The eight pillars emphasise proactive and preventive practices to improve equipment reliability:

• Autonomous maintenance.
• Focused improvement.
• Planned maintenance.
• Quality maintenance.
• Early equipment management.
• Education and training.
• Administrative and office TPM.
• Safety, health and environment.

Together, these pillars support production performance and the activities needed to sustain it.

5. Implementing TPM

An implementation programme can include:

1. Assess the current level of TPM practice.

2. Build awareness and communicate the purpose of TPM.

3. Establish a TPM steering committee.

4. Develop an implementation master plan.

5. Train employees and other relevant participants in the eight pillars.

6. Carry out the necessary preparation.

7. Define the TPM policy, objectives and implementation roadmap.

The steering committee should include production, maintenance and engineering managers and be led by a senior executive. It sets the policy and direction, while a programme team coordinates implementation. Start with a suitable pilot area, demonstrate the approach and use the lessons learned when extending TPM to other areas.

Original article reference: Wikipedia. Additional primary reference: JIPM.

JIPM - About TPM