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TPM Total Productive Maintenance

Updated on October 21, 2009

TPM Definition

A company-wide team-based effort to build quality into equipment and to improve overall equipment effectiveness

Total

• all employees are involved

• it aims to eliminate all accidents, defects and breakdowns

Productive

• actions are performed while production goes on

• troubles for production are minimized

Maintenance

• keep in good condition

• repair, clean, lubricate

TPM combines the traditionally American practice of preventive maintenance with Total Quality Control and Total Employee Involvement, to create a culture where operators develop ownership of their equipment, and become full partners with Maintenance, Engineering and Management to assure equipment operates properly everyday.

 

Origins of TPM

• Dr. Deming introduced statistical analysis and used the resulting data to control quality during manufacturing (TQM)

• Some general concepts of TQM did not work well in the maintenance environment

• The need to go further than preventive maintenance was quickly recognized by those companies who were committed to TQM

• Maintenance became an integral part of TQM in the early 90’s

 

Total Productive Maintenance Principles

• Increase Overall Equipment Effectiveness (OEE)

• Improve existing planned maintenance systems

• The operator is the best condition monitor

• Provide training to upgrade operations and maintenance skills

• Involve everyone and utilize cross-functional teamwork

 

8 Major Pillars of TPM

8 TPM Pillars
8 TPM Pillars

1st TPM Pillar: Autonomous Maintenance

Train the operators to close the gap between them and the maintenance staff, making it easier for both to work as one team

Change the equipment so the operator can identify any abnormal conditions and measure deterioration before it affects the process or leads to a failure

7 steps are implemented to progressively increase operators knowledge, participation and responsibility for their equipment

1. Perform initial cleaning and inspection

2. Countermeasures for the causes and effects of dirt and dust

3. Establish cleaning and lubrication standards

4. Conduct general inspection training

5. Carry out equipment inspection checks

6. Workplace management and control

7. Continuous improvement

 

2nd TPM Pillar: Equipment and Process Improvement

Objective: maximize efficiency by eliminating waste and manufacturing losses

Manufacturing losses are categorized into 13 big losses:

•          Equipment losses (6)

•          Manpower losses (4)

•          Material losses (3)

 

Equipment Losses

Equipment Losses
Equipment Losses

Manpower and Material Losses

Manpower and Material Losses
Manpower and Material Losses

OEE: Overall Equipment Effectiveness

OEE figures are determined by combining the availability and performance of your equipment with the quality of parts made

OEE measures the efficiency of the machine during its planned loading time. Planned downtime does not affect the OEE figure.

 

OEE: Overall Equipment Effectiveness
OEE: Overall Equipment Effectiveness

3rd TPM Pillar: Planned Maintenance

Objective: establish Preventative and Predictive Maintenance systems for equipment and tooling

Natural life cycle of individual machine elements must be achieved

• Correct operation

• Correct set-up

• Cleaning

• Lubrication

• Retightening

• Feedback and repair of minor defects

• Quality spare parts

 

 

4th TPM Pillar: Early Management of New Equipment

Objective: establish systems to shorten

•          new product or equipment development

•          start-up, commissioning and stabilization time for quality and efficiency

New equipment needs to be:

•          easy to operate

•          easy to clean

•          easy to maintain and reliable

•          have quick set-up times

•          operate at the lowest life cycle cost

 

5th TPM Pillar: Process Quality Management

Definition: a process for controlling the condition of equipment components that affect variability in product quality

Objective: to set and maintain conditions to accomplish zero defects

Quality rate has a direct correlation with

•          material conditions

•          equipment precision

•          production methods

•          process parameters

 

6th TPM Pillar: TPM in Administrative and Support Departments.

Administrative and support departments can be seen as process plants whose principal tasks are to collect, process, and distribute information

Process analysis should be applied to streamline information flow

 

 

7th TPM Pillar: Education and Training

TPM is a continuous learning process.

2 major components

• soft skills training: how to work as teams, diversity training and communication skills

• technical training: upgrading problem-solving and equipment- related skills

 

8th TPM Pillar: Safety and Environmental Management

Assuring safety and preventing adverse environmental impacts are important priorities in any TPM effort.

 

Comments

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    • j.r.assis profile image

      j.r.assis 7 years ago from Sao Paulo-Brazil

      Dear Marcel

      Great job about TPM.

    • profile image

      RaghuRamiReddy SS 7 years ago

      Its excellent Job and you to keep sending this type of information too all.

      Lean, SMED,TQM & TPM.

    • profile image

      RaghuRamiReddy SS 7 years ago

      Its excellent Job and you to keep sending this type of information too all.

      Lean, SMED,TQM & TPM.

    • profile image

      RaghuRamiReddy SS 7 years ago

      Its excellent Job and you to keep sending this type of information too all.

      Lean, SMED,TQM & TPM.

    • profile image

      suresh 7 years ago

      good job

      i want to know how to calculate critical spare parts in TPM

    • profile image

      A.M .Somaiah 7 years ago

      It is great that you defined TPM in simple way a layman can understand and implement .

      If calucalations of OEE in batch process multi product chemical industry example is there pl post so helpful for these kind of indusrties.

    • profile image

      avinash 7 years ago

      Dear friend ,

      Your are so kind,and intelligent,

      your work will help to all,

      I am thanking you heartly,you are very nice person.

      avinash

    • profile image

      dev 7 years ago

      you done very well job on TPM. I want to know that Is the TPM is the part of MAintenance department or only little bit count in maintenance department.

      My seniors says that this is work from operator side once you trained the operator. Pl. clear my doubt.

    • profile image

      demet 7 years ago

      Dear Sir,

      Thanks for your sharing...look forward other pages :)

    • profile image

      yogita jaiswal 7 years ago

      Thanks For Sharing.It will Help me a lot

    • profile image

      Jayant Karandikar 7 years ago

      TPM ...explained in simple terms, now we look forward for implementation steps.. very good Thanks a lot

    • profile image

      Rajat Gohil 7 years ago

      thanks a lot pls keep updating

    • profile image

      Bayo 7 years ago

      Great job indeed to have simplified a topic earlier considered technical to a level very convenient for "all" to understand

    • profile image

      Maux 7 years ago

      Excellent job, thanks!

    • profile image

      pradeep deo 7 years ago

      I think u have done a great job in creating this hub and given opportunity to share views.

      I find that in TPM the operator is not ready to assume owner ship of machine.What are the initiatives one should try, to achieve this.(Ownership)

    • profile image

      Dr V.V.R.Sastry 7 years ago

      Excellent.It is so simple and very informative.

    • profile image

      SN AGRAWAL 7 years ago

      It is wonder ful and valuable presentantion of such an impoortant topic and will go a long way to make our people understand TPM.

    • profile image

      Dimpho Bonang 7 years ago

      great material for us engineering student.Thanx

    • profile image

      neeru 7 years ago

      It not only gives vivid information but also pushes the Adrenalin of the reader to gather further information related to the given information and continue the process of learning.

      Great job done.

    • profile image

      Marcos Sanchez 7 years ago

      Dear Marcel..

      Excellent.. thanks for give us this kind of information

      I'm already waiting more..

      Great Job

    • profile image

      Ombogo 7 years ago

      This is great information for continual improvement in maintenance and improvind equipment uptime. cheers

    • profile image

      Raghavan.vms 7 years ago

      Dear Sir,

      Its really helpful to all. One kind request that it will be helpful if you explain more about Safety and Environmental Management pillar.

    • profile image

      DILURAJ 7 years ago

      HI,NICE THING , YOU HAVE DONE A GOOD JOB

    • profile image

      pradeep deo 7 years ago

      Avery good write up on TPM.thanks for sharing.

    • profile image

      yajuvendra bamrara 7 years ago

      very knowledgefull..sir

    • profile image

      Georege Mathew 7 years ago

      Hi, Excellent job, Its helpful to all.Thanks

    • profile image

      pramonoth 7 years ago

      It is great explaination on how to maintenance the asset.... thanks a lot

    • profile image

      Saman Kulatunga 7 years ago

      Very nicely explained. Short and sweet. I will use your presentation to educate our factory floor people about TPM.

      Thanks a lot and hope to read your next article.

      Regards,

      SamanK.

    • profile image

      kundan singh 6 years ago

      hi

      very nice explained short & easy language

      each & everything good knowledge

      thanks

      regard

      kundan singh

      windals precision pvt.ltd uttrankhand rudrapur

    • profile image

      ISAACS OLWAL 6 years ago

      This is a great insight into TPM..Please continue providing such valuable information to all so that processes can be optimized at the lowest cost.

    • profile image

      K. K. Jha 6 years ago

      This detail given in very clear way made me to fully understand and able to make others also to implement in practice .Kindly keep sending such good and nice presentation.

      Regards

      K.K.Jha

    • profile image

      kk 6 years ago

      how to start E & T in TPM?

    • profile image

      Sanjeev Sharma 6 years ago

      Hi,

      Very well written thing help to all to know about TPM

      Thanx for sharing this knowledge.

      Regards

      Sanjeev Sharma

    • profile image

      Vikas Baggar 6 years ago

      It's really a very good and valuable information in a short sip .

      Thanks Buddy!!!

    • profile image

      santosh kale 6 years ago

      very nice information regarding tpm

      with help of above article, any one can easily understand ,what is tpm.

    • profile image

      K.N.Gopalkrishnappa 6 years ago

      Excellent information about TPM

    • profile image

      K.N.Gopalkrishnappa 6 years ago

      Excellent information about TPM

    • profile image

      THYAGARAJU 6 years ago

      It is very clear and understand

    • profile image

      Ben Balaba 6 years ago

      Great information and crystal clear even to the shop floor awareness

    • profile image

      Kumar Rayagiri 5 years ago

      The explanation on 8 TPM Pillars is unique,

      2 out of 8pillars have become foundations for rest of 6.

      This new concept leads us to focus more on foundation pillars.

    • profile image

      Ishwar Lalwani 5 years ago

      Dear Sir,

      It is indeed a very good and informative article written in simple language and in easy to understand even for the beginers like me.

      I would like to convey my sincere thanks for providing a learining oppoortunity to me.Regards.lalwani.

    • profile image

      R.Dhamotharan 5 years ago

      Dear Mr.Marcel

      Excellent article to understand Total Productive maintenance by all. Keep it up.

      with warm regards/R Dhamotharan

    • profile image

      S.Y.Agasimani 5 years ago

      Dear Mr Marcel,

      Whole TPM concept is put in a short and in simple words so that this can be easily go well down to shop floor workforce.

    • profile image

      Vksharma 5 years ago

      Its a good material for us

    • profile image

      koushik ghosh 5 years ago

      If I got or something about it then it is very helpful for me.

    • profile image

      FAUJDAR 4 years ago

      THANKS FOR LOT OF LEARNING BY TPN

    • profile image

      Siddesh CS 3 years ago

      Short and sweet information about TPM .It helps us to learn & understand the concept of TPM.

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